Donaldson PowerCore 4X4 XLC200K Installation and maintenance instructions

INSTALLATION & SERVICE
INSTRUCTIONS
PowerCore®4X4
XLC200K - Air Cleaner Housing and Filter Kit
Donaldson Company reserves the right to change design and specifications without prior notice. Do not make any system
modifications or adjustments that would alter the original design. Modifications may result in denial of warranty coverage. Consult
your Donaldson representative if you have questions regarding the assembly, operation, maintenance or warranty. Illustrations are for
reference only as actual product may vary.

Read these instructions carefully before using this product, paying particular atten-
tion to all sections that carry warning symbols, caution symbols and notices. Ensure
that these are understood at all times.
WARNING!
This symbol is used whenever there is a risk of personal injury.
CAUTION!
This symbol is used whenever there is a risk of damaging your
Donaldson product.
NOTE:
This symbol is used to provide additional information, hints and tips.
IMPORTANT INFORMATION
These recommended installation procedures and instructions are a partial list intended only as
a guide. If you are not qualified to undertake this installation, do not attempt it as you may be
liable for resulting engine failure.
Before installation, inspect product contents for any damage and ensure you have all
components required.

Contents Description Qty
PowerCore®4X4 Air Cleaner
Housing & Filter Kit
Air Cleaner Housing 1
Air Filter Element 1
Brackets 2
Bracket Isolators 3
Restriction Indicator 1
Wading Plug 1
Foam Sealing* 1
Mounting Bracket Fixtures
M8x16 Bolts 6
M8 Spring Washers 6
M8 Flat Washers 6
MAF Sensor Assembly to Cover
Outlet Fixtures
M4x10 Caphead Bolt 2
M4 Spring Washers 2
M4 Flat Washers 2
Housing Assembly Fixtures
M6x40 Bolt 3
M6 Spring Washers 3
M6 Flat Washers 3
1
2
6
3
4
7
5
Outlet
Inlet
Housing Body
Service Cover
Filter Element
Restriction Indicator
Top Mounting Bracket
Bottom Mounting Bracket
MAF Sensor Connection
1
2
3
4
5
6
7
• 10mm & 13mm socket and socket ratchet wrench with extension bar
• 3mm hex allen key
• Medium phillips head screwdriver
KIT CONTENTS
Please ensure that the engine is off before installation.
Remove product contents from packaging and inspect for any damage. Do not install if there is
any product damage and contact Donaldson immediately.
Required Tools and equipment
XLC200K Kit Contents
* only required when a snorkel is not installed.

1. Disconnecting the Mass Air Flow Sensor (MAF)
• Unclip wiring harness from MAF sensor on the OE
housing outlet and top cover.
2. Disconnect Intake Pipe
Clean housing inlet and outlet clamp area
with a clean damp cloth before loosening the
clamps.This will reduce exposing the engine to
contamination.
• Loosen clamps and remove intake and outlet pipe
from the OE housing.
• Cover intake pipe with a clean cloth to stop
contaminant getting through to the engine and
adjust pipe to a 90-degree upwards angle for ease of
housing removal.
3. Remove OE Housing
• Unscrew the 3 OE housing mounting screws and
completely remove the housing.
• Remove MAF sensor assembly carefully by undoing
the screw sets and set aside.
If using a dual battery setup, be sure to release
the cable clip for the battery earth lead from the
OE housing using a small flat blade screw driver.
INSTALLATION
Removing the Original Equipment Air Filter Housing Assembly
Please ensure that the engine is off before installation.

1. Insert Wading Plug
• Insert the provided wading plug into the drain hole
located on the bottom of the air cleaner.
2. Secure mounting brackets to air housing
• Secure top and bottom mounting brackets to the air
housing using the provided stainless steel M8 bolt
pack (bolt, spring washer, washer)
• Ensure rubber isolators are fitted to the brackets
properly. If isolators are loose, remove the insert
collar, fit rubber mount to the bracket and reinsert
inner insert collar.
3. Installing MAF sensor assembly to housing
• Secure OE MAF sensor assembly to the service
cover outlet using the provided stainless steel M4
bolt pack (bolt, spring washer, washer).
4. Install the housing
• Place housing body into the engine bay and align
the inlet tube with either the guard duct or the
snorkel connector. If using a snorkel, fit connector
and leave clamp loose.
Connecting the intake pipe from the engine
to the outlet of the housing on initial
installation may be easier before securing
the housing with supplied mounting
hardware.
• Secure housing in the engine bay using the
provided zinc plated M6 bolt pack.
• Connect intake tubing to the housing outlet, align
the tubing and secure clamps
• Connect MAF sensor wiring harness to MAF sensor
connection.
• Screw filter service indicator in position and reset.
Fitting PowerCore®4X4 Air Cleaner Housing & Filter Kit
The retrofit housing is delivered as a complete air cleaner assembly.The filter element has
already been installed in the housing.

Air filter service life should be determined by measuring airflow restriction - not by visual
inspection. Replace the filter only when the restriction level has reached the maximum
recommended by the engine manufacturer or on a regular scheduled service.
SERVICE & MAINTENANCE INSTRUCTIONS
Please ensure that the engine is off before installation.
Remove product contents from packaging and inspect for any damage. Do not install if there is
any product damage and contact Donaldson immediately.
1. Inspect service indicator
• Visually inspect the ‘Service When Red’ gauge
on the service indicator. When this section is
completely red, it is time to change your air filter.
Cleaning housing outlet clamp area with a damp
cloth before loosening the clamp will reduce
exposing the engine to contamination.
2. Removing the service cover and air filter element
• Loosen clamp at engine intake and at the housing
outlet.
• Remove piping from the air housing outlet, cover
piping with a clean cloth to stop contaminant
getting through to the engine and adjust pipe to
a 90-degree upwards angle for ease of cover and
element removal.
• Release the 2 cover latches, tilt service cover
forward to remove from housing body and set
aside.
• Remove filter element from housing. After
removing the filter, wipe the air cleaner housing
interior and seal surface with a clean, damp cloth.
3. Inspect wading plug
• If wading plug is broken or missing, replace it.

4. Installing the new filter element
Take extra care to ensure the element is seated
correctly in position and the urethane seal is
sitting flat on the housing sealing surface.
• Insert the filter element into the housing, locating
the tabs of the housing to the pockets of the
element until the gasket contacts the housing.
Correct positioning is achieved when gasket is
sitting flat on the housing sealing surface.
Take care to align the cover correctly. There
should be minimum resistance when fitting the
cover if everything is aligned properly.
5. Fitting the service cover
• Place service cover in position and fasten the metal
latches. If the cover doesn’t align correctly remove
and re-check the filter position and service cover
placement.
• Reconnect intake tubing to the housing outlet. Align
the tubing and secure clamps.
• Reset the service indicator.

P903920 (ENG), Revision 0 (November 2022) © 2022 Donaldson Company, Inc. All rights reserved. Donaldson
Company, Inc. reserves the right to change or discontinue any model or specification at any time and without
notice. Printed in Australia.
Donaldson Australasia Pty Ltd
PO Box 153, Wyong NSW 2259
Freecall: 1800 345 837
Ph: [phone]
Fax: [phone]
Donaldson New Zealand
PO Box 14-770, Panmure 1741 Auckland
Ph: [phone]
Fax: [phone]
donaldson.com/powercore-4x4
Why Choose Donaldson?Why Choose Donaldson?
PERFORMANCEPERFORMANCE
First-fit choice of leading equipment
manufacturers around the world.
INNOVATIONINNOVATION
Continuous development of new technologies
to meet changing filtration needs.
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Knowledgeable technical support specialists
available in-field when you need them.
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Comprehensive warranty covering our filters
and your equipment.
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providing local support.
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manufacture and delivery of every product.
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