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Exhaust System Guide

Exhaust System Overview

• HowtheExhaustSystemWorks

• Components

• ImportanceofCorrectBackPressure

• ReplacingtheSystem

Exhaust System Basics

• Construction

• Applications

• Troubleshooting

• Warranty

Exhaust System Components

• StackPipes

• ExhaustClamps

• RainCaps

• HeatGuardsandGrabHandles

• FlexibleTubing

Nelson Global Products, Inc. designs and manufactures the highest quality exhaust system components to reduce noise and protect our environment. This study guide provides a product overview, including the importance of each component in the exhaust system and the available options for ordering each product.

Nelson Global Products, Inc. Warranty to the Original Equipment ManufacturerExhaust Products Limited Warranty

Warranty:ThisWarrantyisprovidedtoeachoriginalequipmentmanufacturer(OEM)withitspurchaseofanyoftheNelsonGlobalProducts,Inc.productslistedinthetablebelow.AnyNelsonGlobalProducts,Inc.productdeterminedbyNelsonGlobalProducts,Inc.tobedefectiveinmaterialorworkmanshipwill,atNelsonGlobalProducts,Inc.election,bereplacedbyanotherNelsonGlobalProducts,Inc.productorbyacreditfortheoriginalNelsonGlobalProducts,Inc.sellingpriceoftheproduct.IntheeventthatsuchaNelsonGlobalProducts,Inc.productdefectnecessitatesrepairoftheengineorcomponents,NelsonGlobalProducts,Inc.willreimbursetheOEMreasonablecoststorepairorreplace,whicheverisless,thedamagedengineorcomponentstoaconditionequivalenttothatexistingjustpriortothefailure.

AnyclaimunderthisWarrantyforreplacementorcreditmustbesubmittedinwritingtoNelsonGlobalProducts,Inc.withinthirty(30)daysofdiscoveringtheclaimeddefect.

ForthepurposeofreviewingWarrantyclaimvalidity,NelsonGlobalProducts,Inc.oritsrepresentativeswill,atNelsonGlobalProducts,Inc.discretion,havetherightto:

a. Physicallyinspecttheclaimeddefectiveproductand/orequipmentusingtheproduct.

b. Informationavailablefrompurchaseroruserrelativetotheactualapplicationand/oruseandmaintenanceoftheproduct.

Duration: ThisWarrantyextendsfromthein-servicedateoftheNelsonGlobalProducts,Inc.productinstalledbytheoriginalequipmentmanufacturerthroughthedurationoftheOEM’sbasewarranty,butwillnotexceedthecoverageperiodstatedinthetablebelow.

Limitation: NelsonGlobalProducts,Inc.isnotresponsibleforproductfailuresand/orrepaircostsresultingfrommisuse(e.g.notallowingthemufflertocoolwhichcausesanafterfireevent),faultyinstallation,alteration,misapplication,faultymaintenancepractices(e.g.cleaningorservicingofsparkarrestors),neglect,oraccident;norisNelsonGlobalProducts,Inc.responsiblefordowntime,lossofincome,livingexpenses,orotherincidentalorconsequentialdamages.Unlessotherwiseagreedtoinwriting,thisWarrantyisthesolewarrantymadebyNelsonGlobalProducts,Inc.NELSONGLOBALPRODUCTS,INC.MAKESNOOTHERWARRANTIES,EXPRESSORIMPLIED,OFMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSE.

Exhaust Products Warranty Coverage Periods for Nelson Global Products, Inc.

Duration of Warranty period (whichever occurs first)

Application / Product YearsDistance

(miles/km)On-Highway

Heavy Duty (Class 8) 1 100,000 / 161,000

Medium Duty (Class thru 7) 1 100,000 / 161,000

Transit Bus 1 50,000 / 80,500

Coach bus 1 100,000 / 161,000

Off-highway 1 N/A

Product / Parts

Mufflers – O.E. / Std. Line 1 N/A

Tubes – Formed / Assemblies 1 N/A

Accessories - clamps, rain caps, heat-shields, adaptors, etc.

1 N/A

Pre-treatment exhaust assemblies * 1 N/A

Post-Treatment exhaust assemblies * 1 N/A

Chrome or aesthetic coated components 1 N/A

Flex pipe (interlocking/bellows design) None Sold “as is”

Retrofit kits 1 100,000 / 161,000

Catalytic Exhaust Mufflers – Gas/Diesel 1 100,000 / 161,000

* Note:Purchaserisresponsibleforallapplication,enduranceandverificationtestingpriortoproductionrelease.

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Table of Contents

Introduction........................................................................................4FiveWaystoReduceNoiseLevels................................................5ObjectivesOfThisManual...........................................................5ForMoreInformation...................................................................5AnOpportunityToTestYourself...................................................5

ExhaustSystemOverview..................................................................6HowTheExhaustSystemWorks..................................................6ExhaustSystemComponents......................................................6TheImportanceOfCorrectBackPressure...................................7HowToReplaceTheSystem.......................................................7StudyQuestions..........................................................................8

ExhaustSystemBasics......................................................................9TopQualityConstruction...............................................................9OriginalVersusEconomyEquipment:TheChoiceIsYours.......... 10TheNelsonGlobalProductsDifference...................................... 10Applications................................................................................11HowtoTroubleshoottheExhaustSystem...................................12ExhaustSystemProductsWarranty...........................................12StudyQuestions........................................................................12

NelsonGlobalProductsExhaustSystemComponents.................... 13StackPipes............................................................................... 13ExhaustClamps........................................................................14RainCaps..................................................................................14HeatGuardsandGrabHandles.................................................14FlexibleTubing...........................................................................15StudyQuestions........................................................................16

GlossaryofTerms............................................................................17

FinalReviewExercise.......................................................................18

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Introduction

Overtheyears,theexhaustsystemhasbeengivenmoreresponsibilityanditsjobhasgrown.Originally,itwasarelativelysimpleductsystemdesignedtopreventtoxicexhaustgasesfromenteringthedriver’scab.Today,themoderndieselexhaustsystemreducesnoiseandevenlendsahandwithincreasingavehicle’sfueleconomy,powerandoveralldriveability.

Yes,it’sanotherstoryofchange.Changesthroughouttheindustry.Changesingovernmentalregulation.Changesinconsumerdemands.

IntheUnitedStatesduringthepast30years,federal,stateandlocalgovernmentshaveintroducednoisepollutioncontrol.TheFederalNoiseControlActof1972wasthefirstnationwidelawtoregulatetrucknoiselevels.Thisregulation,whichfirstwentintoeffectinOctober1975,limitedtotaltrucknoiselevelsto86dB(A),measuredat50feet(15.24m)forspeedslessthan35mph(56.35km/h).InJanuary1978,thisnoiselevelwasreducedto83dB(A);followedbyanotherreductioninJanuary1988,whenthenoiselevelregulationwasloweredtothecurrent80dB(A)level.

AccordingtoAustraliadesignrule28/01in2006,noiseregulationisbasedonadifferenttestingmethod.Thesoundmeasurementistakenat24.61feet(7.5m)forspeedsof31.07mph(50km/h).Dependingonthevehicle’shorsepower,thesoundrequirementrangesfrom81-87dB(A)forheavygoodsvehicles.

InEurope,thenoiseregulationhasbeenupdatedmanytimessince1970.ThelatestamendmentwasJune6,2007,whichspecifiedthatforheavydutytruckswithanenginehorsepowerofnotlessthan150kW,thenoiselevelcannotexceed80dB(A)measuredat24.61feet(7.5m)forspeedsof31.07mph(50km/h),accordingtoDirective70/157/EEC.

InChina,fortruckswithanengineover150kWproducedafterJanuary1,2005,thenoiselevelscannotexceed84dB(A).Thesoundmeasurementistakenat24.61feet(7.5m)forspeedsof31.07mph(50km/h).Besidesthenoise,otherby-productsofenginecombustionareexhaustparticlesandgasesemittedintotheexhaustsystem.Legislationtocontrolthelevelsoftheseemissionsoccurredin1988,1990,1991,1994,2004,and2007.Eachregulatorychangereducedtheacceptablelevelsofcombustion-relatedgaseswhichcouldbeallowedtoexittheexhaustsystem.

Tomeettheseemissionlaws,NelsonGlobalProductsworkscloselywithallengineandtruckmanufacturerstoprovideexhaustsystemcomponents.Asthegloballeaderinexhaustdesign,NelsonGlobalProductsdevelopsandprovideshighlyspecializedexhaustsystemsthatreducenoiseandminimizeharmfulgases.

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Introduction

Five Ways to Reduce Noise LevelsTherearefiveprimarysourcesthatcontributetothenoiselevelofahighwaytruck.

1 - Fan Noise Excessivefanspeedisacommoncontributingnoisesource.Thiscanbecontrolledbytheuseofatemperaturecontrolledorthermostaticfan.Othernoiseconcernsarebentfanbladesandbrokenormissingshrouds.

2 – Air Intake Boththetypeofsystemandthelocationoftheinletaffectthetrucknoiselevel.Airinletsthatopentothesidearegenerallynoisierthanthosethatdonot.Intakeairsilencersareavailableforproblemapplications.

3 – Mechanical Noise Theengineanddrivetrainarealsoasourceofnoise.Operatingspeed,typeofengineanddrivetrainallaffectthetotalnoiselevel.Shieldingtheexposedareaswithacousticbarrierswillreducenoiselevels.Generally,anypartoftheengineordrivetrainthatcanbeseenwhilestandingawayfromthetruckwillcontributetothetotalvehiclenoiselevel.

4 – Tires Manytimesthisisthemajornoisesourceforhighwaytruckstravelingathighspeeds.Theconditionofthetiresandthetreadpatternaffectthenoiselevel.Atlowspeeds,thisisnotalargenoisesource.

5 – Exhaust System Wornorinadequateexhaustsystemsarethelargestandthemostfrequentcontributortohighnoiselevels.Avisualinspectionandrepairofleakingconnectionsorreplacementoffailedcomponentswillnoticeablyreducenoiselevels.Ifthenoiselevelisstilltoohigh,theadditionofresonators,packedstacksorachangeinmufflersisrecommended.

Objectives Of This Manual Mostofushaveagoodideaofhowtheexhaustsystemworksandwhy.Evenso,youmaynotrealizethatincompatibleorinferiorexhaustsystempartscanshortencomponentlife,interferewithpropervehiclefunctionandmayevencauseseriousdamage.Highqualityreplacementpartsarecriticalandinthepagesaheadyou’lllearnwhy.Inthisguide,youwillalso:

• Masterabasicunderstandingoftheheavyandmediumdutyexhaustsystem.

• Learnhowspecificexhaustcomponentsandrelatedpartsaffectoverallvehicleperformanceandfuelefficiency.

• RefreshyourbasicknowledgeaboutEPAregulationsrelatedtoexhaustnoise.

• ReviewtheNelsonGlobalProductslineofexhaustsystemproductsandrelateditems.

For More Information Atthesametime,youmayhavequestionsaboutspecificapplications.Inthatcase,weencourageyoutovisitourwebsiteatnelsonglobalproduct.com.

An Opportunity To Test Yourself Youwillfindstudyquestionsattheendofeachchapter.Thesequestionsareprovidedasatooltohelpyoureviewthematerialandcommittheinformationtomemory.YouwillalsofindtheFinalReviewExerciseatthebackofthemanual.Thismultiple-choicereviewprovidessomeadditionalpracticeandchecksyourmemoryonthesubjectmatter.

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Exhaust System Overview

How The Exhaust System WorksTheprimarypurposeoftheexhaustsystemistoexpelburnedgases—orexhaust—totherearofthevehicleandtodampenthesoundofenginecombustion.

Rain CapMuffler

Stack Pipe

ManifoldPipe

ExhaustPipe andElbows

Exhaust System Components Themajorpartsofadieseltruckexhaustsysteminclude:

• Manifold

• Manifoldpipeandconnector

• Exhaustpipesandelbows

• Muffler

• Stackpipeortailspout

• Clamps

• Resonators

Let’sreviewtheprimarycomponentsoftheexhaustsystem—andhowtheyworktogethertoexpelexhaust,reducenoiseandassistinsmootherrunningoperation.

Manifold Althoughthemanifoldisoftenthoughttobeapartoftheengine,itisakeycomponentoftheexhaustsystem.Theexhaustmanifoldisthecomponent,usuallymadeofcastiron,thatgathersalltheexhaustasitcomesoutoftheheadintoasinglecollector.Themanifoldthendeliverstheburnedgasesintoexhaustpipes.

Theprimarypurposeoftheexhaust pipes istoserveasanenclosedroutefortheburnedgasestoexitthesystem.Whileexhaustpipesarejoinedtothemanifoldbyamanifoldpipe/connector,thereareavarietyofwaystoassemblethe“route”orsystem.

Forexample,averticaldualexhaustsystemwouldutilizeamanifoldpipewithasplitterteeadaptertoroutetheexhaustintwodifferentdirections.Ontheotherhand,aWye ConnectorwouldbeusedinaV-typeengineapplication,typicallyamediumdutytruck.Therearealsomufflerswhichfeaturetwoinlets—oneforeachhalfofaV-typeengine—leadingtooneoutlet.

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Exhaust System Overview

Exhaust Pipe and Elbows Exhaust pipes and elbowshaveseveralimportantpurposes.Exhaustgasistoxic,andtheseexhaustpipesservetocontaintheexhaustandrouteittowardstherearofthevehicleasquicklyandefficientlyaspossible.Thepipesandelbowsareusedtocreateaneffectivelysealedpathwaytoguidetheexhaustgassafelyfromtheenginetotheexteriorofthetractor/trailer.Exhaustpipesaremanufacturedinawidevarietyofshapesandsizes,althoughtherearebasicallytwotypes:

• Regularpipe

• Flexiblepipe

Regular exhaust pipeissolid,typicallyavailableinstraightlengths,bentconfigurationsandelbows.

Certainapplicationsalsorequireflexibilitybecausetheconnectionmustbesealedtightly.Atthesametime,theexhaustsystemmustbeflexibleenoughtobendwithroadconditionsandaccommodatethermalexpansionofthesystem;otherwisethepipeoraconnectionmaysnaporbreak.Thatiswhyflexible exhaust pipeiscommonlyusedinlargerdieselexhaustsystems,heavydutyapplicationsandsevereservicevehicles.

Theexhaustsystemmaybesealedbyweldingjoints.Alternatively,insteadofwelding,exhaust clampscanbeusedinplaceofweldingasasimple,effectivewaytosealoverlappingpipes.Asidefromschoolbusapplications,whichincludesomeextremelystrictrequirementsandregulations,themethodforsealingthesystemisapersonalpreferenceoftheownerorfleetmanager.

Therearealsoapplicationswhereresonator(s)areusedtobegintodampenthenoisebeforeitreachesthemuffler.

Muffler Themuffleristheprimarycomponentwithintheexhaustsystemthatreducesthenoisemadebytheengineduringcombustion;assoundwavesenterthemufflerchamber,theyarebrokenupandthenoisedissipates.

Sometypesofmufflersincludechamberswithholes,whileothersarepaddedwithfiberglassorplatestodampennoiselevels.Thetechnical

challengeistouseamethodthatmosteffectivelybreaksupsoundwaveswithoutproducingexcessivebackpressure.Somemufflersstartwithamoreefficientdesignthanothers,useheaviergaugematerialsandrelyonbettermanufacturingprocesses—andtheseallmakeanoticeabledifferenceinquality,maintenancecostsandvehicleperformance.

The Importance Of Correct Back Pressure Exhaustgasesarepassedthroughthemufflertoreducethenoiseofenginecombustion.Atthesametime,backpressurecausesexhaustgasestoremainintheenginecylinderaftertheexhauststroke.Whileacertainamountofbackpressureisvitaltooptimumperformance,toomuchbackpressurecanresultinlossofhorsepowerandexcessiveengine/turbochargeroperatingtemperatures.Whenthishappens,performanceandfueleconomysuffer.Itmaynottakemuchtoalterthebalanceortoaffectengineoperation.

Alwaysreplacecomponentsintheexhaustsystemwithlikecomponents.Whenthevehiclewasdesigned,productengineersselectedspecificexhaustsystemcomponentsandpartstoachieveahighperformancebalance,includingtheproperamountofbackpressure.Replacinganexhaustsystempartwithalikecomponentassuresthemostefficientperformance.

How To Replace The System Whenyouconsiderreplacingamuffler,that’sthetimetothinkaboutreplacementpipe,newclampsorotherrelateditems.Ifanewmufflerorpipeisinstalledandthereisstillanexhaustleak,theproblemisnotfixed.

ThebestwaytoselectamuffleristousetheOEpartnumbercrossreference.IftheOEnumberisnotavailable,usea“MufflerApplicationByEngine”reference.Manymufflershavethesameexteriorsizebutvastlydifferentinteriorconstructionandperformance.

Thereareseveralotheritemsyouneedtoconsiderbeforeanyexhaustsysteminstallationorrepair.

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Exhaust System Overview

• Use new clamps anytime a muffler or pipe is replaced.Thisisalsoagoodtimetodouble-checkallotherclampsandjointswithintheexhaustsystem.

• Thoroughly review the system for special needs,suchasraincaps(forastraightstackpipe)toprolongthelifeofthesystem.Makesureanexistingraincapisstillinplaceandingoodcondition.

• On a vertical system, check to ensure that the heat guard around the muffler is in place and secure.Ifthereisnoheatshield—youmaywanttoconsideraddingone.

• Check the system for other components that may need to be replaced.

• Examine the flex pipe(ifitisused)tomakesureit’singoodconditionandwillperformproperly.

• Startingatthefront,do a leak checkallthewayback.Themanifoldpipe/connectorneedstobecheckedeverytimeanyworkisdoneontheexhaustsystem.

• Once the system is assembled, it should be checked for leaksafternewclampsareputintoplaceand/orweldingiscomplete.

Welding Aluminized Steel

Oxyacetylene Welding Filler Metal Useamildsteelfillermetal,3/32"(2.38mm)diameter,freeofrust(AmericanWeldingSocietyclassificationA5.2).Donotusecoppercoatedfillermaterial.

Welding equipment:Useanumber3or4tip.Observeinstructionsoftheequipmentmanufacturerwhenadjustingtheoperatingpressuresatthegasregulators.

Procedure:Cleanthepartstobeweldedthoroughly.Inclinethetorchata45°anglefromthedirectionoftravel.Usetheforehandweldingtechnique.Keepthetorchflameonthetipofthefillerrod,notinthecenterofthepuddle.

Shielded Metal-Arc (Stick Electrode) Anyoneofthefollowingrodsarerecommended:

• E6011

• Lowhydrogen:E7018

• Stainless:309or310

Gas Metal-Arc (MIG) • Wire:ER70S-3orER70S-6

• Shieldgas:CarbonDioxideor75%Argon25%Co2

Study Questions

1. Eachofthefollowingisoneofthefiveprimarysourcesthatcontributetothenoiselevelofahighwaytruckexcept:(Reference,pg.5)

a. Engineanddrivetrainb. Fuelsystemc. Exhaustsystemd. Airintake

2. The______________istheprimarycomponentwithintheexhaustsystemthatreducesthenoisemadebytheengineduringcombustion;assoundwavesenterthe______________chamber,theyarebrokenupandthenoisedissipates.(Reference,pg.7)

a. Manifoldb. Wyeconnectorc. Resonatord. Muffler

3. Whenspecifyingreplacementparts,oneofthemostimportant“rules”torememberisthis:Alwaysreplacecomponentswithlikecomponents.Whyisthissoimportant?(Reference,pg.7)

a. ItisamandatoryrulingoftheFederalNoiseControlActof1972.

b. OEM-specifiedmufflersaretheonlylegalapplicationincertainstates.

c. Mufflerscouldhavethesameexteriorsizebuthaveverydifferentinteriorconstructionandperformance.

d. Thereislittledifferencebetweenmufflers.

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Exhaust System Basics

Top Quality ConstructionHeavyduty,mediumduty,andmostrecently,lightdutyexhaustproductsaremanufacturedbyNelsonGlobalProducts,thelargestOEMsupplierofexhaustsystemsandaleaderinengineexhaustnoisetechnology.YoucancountonNelsonGlobalProductsexhaustsystemproductsforOEqualityalongwithconsistent:

• Quietoperation

• Lowbackpressure

• Fuelefficiency

Asthegloballeaderinthedesignofexhaustsystemsthatmaximizeperformanceandminimizeenvironmentalimpact,NelsonGlobalProductsprovidestheindustry’shighestqualityproductsunderitsNelsonGlobalProductsbrand.NelsonGlobalProductsexhaustsystemsaredesignedfordurabilityandcustomtunedtomeetcurrentnoiselevelregulations.TheNelsonGlobalProductsproductlineincludesmufflers,non-chrometubes,stacksandelbows—allpremiumcomponentsconstructedoftop-gradesteel.Thesteelisaluminized,whichmeansitistreatedtoresistthecorrosiveactiongeneratedbyheavydutyexhaustsystems,eveninhightemperatureconditions.

TherearenumerousdesignfeaturesthatmakeNelsonGlobalProductsmufflerstoprate.Perhapsthemostimportantisthefloatingbaffledesign,patentedbyNelsonGlobalProducts,thatreliesonaseriesofsmallpartitions(orbaffles)toimpedesoundwavesformaximumnoisereductionwithoptimalbackpressure.Theperforatedtubesandresonatorchambersontheinsideofthemufflerkeepnoiselevelsdownwithoutrestrictingtheflowofexhaustgas.

NelsonGlobalProductsmufflersareconstructedofheavygaugealuminizedsteelto:

• Resisthot,corrosiveexhaustgases

• Deterrust

• Extendservicelife

Manyofthesmalldiameterhorizontalmufflersalsofeatureaheavydutycrimpconstructiononbothends.Thisuniquefeature,approvedbyOEMs,makesahigh-strength,backfire-proofandrust-freeseal.Verticalmufflershavespecialedgeweldingtoprovideastrongjointthatisalsoappealinginappearance.Besidesthissmoothedge,themufflerhasadomedheadwhich,onverticalapplication,preventsmoisturefromcollectingatthetopofthemuffler.

NelsonGlobalProductsalsooffersaneconomymufflerthatgoeshead-to-headwiththecompetition,featuringheaviergaugeflangesaswellasinternalflangesforsupport.TheillustrationonthefollowingpageshowsthedifferencebetweenNelsonGlobalProductsOEandNelsonGlobalProductseconomymufflers.

Whetheryouneedthefull-featureperformanceofanOEreplacementoryou’relookingforalowercostsolution,thebestchoiceisNelsonGlobalProducts.

Final Review Exercise Answers: 1.d 2.a 3.a 4.c 5.b

6.c 7.b 8.b 9.d 10.a

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Exhaust System BasicsOriginal Versus Economy Equipment: The Choice Is Yours

The Nelson Global Products Difference

Aluminized Steel WhyareNelsonGlobalProductsmufflerssomuchbetterthanwill-fitmufflers?WhyshouldyoubuyaNelsonGlobalProductsOEMapprovedmufflerinsteadofanaftermarketnon-certifiedcopy?Theanswerstartswiththesteel.Theaverageexhaustsystemtemperaturesofgasanddieselapplicationsrangefrom800°F(427°C)to1400°F(760°C).

Aluminized steelholdsitsstrengthcharacteristicsupto1300°F(705°C).NelsonGlobalProductsaluminizedsteelalsoresistsoxidationmuchlongerthanunprotectedmildsteel.

Unprotected mild steel usedbymanywill-fitcompaniesbeginstorustassoonasitisexposedtoeverydayfieldconditions,regardlessofitsthickness.Thismildsteelalsolosesitsstrengthafterexposuretominimumexhausttemperatures.

Galvanized steelbeginstogiveoffextremelytoxicfumesattheminimum800°F(427°C),andimmediatelylosesitsrustresistantcharacteristics.

ThesuperiorityofaluminizedsteeliswhyNelsonGlobalProductsusesallaluminizedsteelconstructionforitsexhaustmufflers,non-chrometubes,stacksandelbows.

Original Equipment (OE)Muffler

Economy Muffler

All Aluminized Steel Construction

1300°

800°

800°

• OriginalEquipmentMufflersreduceexhaustnoisetolevelrequiredtomeetEPAtrucknoiselimits.

• OriginalEquipmentMufflerscanbequieter(morethan3dBA)thanEconomyversion,dependingonmakeofengine.

• OriginalEquipmentMufflersarecoveredbyNelsonGlobalProducts’500,000mileorfouryearwarranty.

• NelsonGlobalProductshas16gaugeendflange.(Somecompetitor'sarelighter.)

• LocalnoiselawsshouldbecheckedbeforeusingEconomyversion.

• EconomyMufflersarenotcoveredby500,000mileorfouryearwarranty.

• NelsonGlobalProductsincludesaninternalsupportflange.(SomeCompetitor'sdonot.)

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Exhaust System Basics

ApplicationsWhenitcomestoexhaustsystems,therearetwobasicconfigurations—verticalandhorizontal.Ifyoucompareactualcomponentsinthesketchesofthesetwosystems,you’llseethatthereislittlevariationinparts.

Vertical Applications Withtoday’sverticalapplication,themufflerisboltedtoamaststructure.Inthepast,mufflerswereboltedtothebackofthecabortractor;however,thisresultedinagreatdealofnoisetransfer.That’swhythemajorityoftrucksnowuseamaststructurewithseparatesupportsofftheframeformounting.

Rain Caps

Stack Pipes

Mufflers

ExhaustElbow

ManifoldConnectorManifoldPipeSplitter Tee

Adapter

Exhaust PipeStraight or Flexible

TubingResonators

Exhaust Elbows

Vertical System

Thisschematicshowsthe“plumbing”–orallofthecomponentsandexhaustsystempartsneededforaverticalapplication.Althoughthisshowsadualexhaustconfiguration,thiskindofexhaustsystemcanalsobeinstalledasasingleexhaustconfiguration.Youmaypreferthisverticalstacksystemasawaytogetanyobjectionableexhaustodorawayfromgroundlevel.However,thereisnoregulationortechnicalrequirementforoneconfigurationovertheother;thischoiceissimplyamatterofpersonalpreference.

Horizontal Applications Inrecentyears,theindustryhasbeguntofocusmoreonaerodynamics,soithasbecomemorepopulartouseahorizontalexhaustsystem.Mufflersandstackpipesthatstickup(asinaverticalapplication)causeparasiticdragandcan

detractfromfuelmileage.So,insomecases,thechoiceismadetoputtheexhaustsystemunderneaththetractortrailer.Again,thisisstrictlyapersonalpreference.

Tail Spout

Mufflers

ExhaustPipe

Resonators

Exhaust PipeStraight or

FlexibleTubing

WyeConnector

ManifoldConnector

ManifoldPipe

Horizontal System

Insomecases,theresimplymaynotbeenoughroombetweenatractorandtheboxinastraighttrucktoinstallaverticalexhaustsystem.Atthesetimes,ahorizontalconfigurationistheidealsolution.

What’simportanttorememberisthatitispossibletofindaverticalandahorizontalapplicationinanytruckclass.Oneconfigurationmaybettersuitaparticulartruckduetospaceconstraints,butinmanycases,thisisachoicebasedonpastexperienceand/oranindividualpreference.

School Bus Applications Schoolbusapplicationsareanexceptiontothematterofpersonalpreference.Infact,therearesomeverystringentlocalregulationsforschoolbusexhaustsystems,possiblyincludingrequirementsfor:

• Ahorizontalapplication

• Rearexit

• Atotallyleakfreesystem

NelsonGlobalProductsoffersthemostcompleteproductcoverageinthebusaftermarketwiththeflexibilitytomeetyourmostrigorousrequirements,includingthehighqualityassuranceandlonglifevitaltothisspecializedmarket.

Off-Road Exhaust Systems and Special Mufflers Wealsoofferaseriesofmufflersandaccessoriesforoff-highwayequipmenttailoringOEMs.PleaseseeourExhaustSystemsCatalog(NPG005)fordetails.

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How to Troubleshoot the Exhaust SystemThefollowingareguidelinestohelpyoulocateandidentifyproblemareasinthevehicle’sexhaustsystem.

• Mufflers.Inspecttheareaaroundclampsforbreakage,cracksandrust-through.Inadditiontoexcessnoise,aleakinthemufflercancausecleanupexpenseswhensootescapesanddiscolorsthecabortrailer.Mostimportantly,aleakingmufflermayallowexhaustgasestoescapetothedrivercompartmentcausingsleepinessandevendeaththroughcarbonmonoxidepoisoning.

• Elbows, Stacks and Exhaust Pipes.Dentsorcrushedportionsofanytubingcreateexhaustflowrestrictionandincreasebackpressuresignificantly.Evenrelativelysmalldentswillcausedecreasedfueleconomyandincreasedturbowear.Ifdentsarerelativelylarge,increasedbearingandlowercylinderwearwilloccurduetoincreasedexhausttemperature.Insuchcases,significantdecreasesinfueleconomywillresult.

• Rain Caps.AlthoughNelsonGlobalProductsmufflersaredesignedtopreventrain,meltedsnowandsleetfrompassingbeyondthemufflertotheengine,raincapsarerecommended.Waterenteringthemufflerwillcreateaslurryofsoottobeblownonthetrailercausingsignificantcleanupexpense.Acurvedexhauststackisanacceptablealternativetoaraincapbutmaynotbe100%effectiveinhardrains.

• Clamps.Checkbandclampsforcrackingperiodically.Reuseofanyclampsisnotrecommended.

• Flexible Tubing.Donotpatch.Replaceentiresection.Stainlesssteelisrecommendedasthebestvalue.

• Mounting.Theexhaustsystemshouldbesecuredtoeliminatevibration.Themufflerbracketsshouldfitsecurelytothemufflerandtothemastortruckframe.Themufflerbracketsshouldnotsqueezethemufflerbodyandthemastmustnotvibrateorwiggle.

Exhaust System Products Warranty Perhapsthemostcommonlyreplacedexhaustsystemcomponentisthemuffler.Infact,industrydataindicatethatheavydutymufflersarereplacedeverythreetofouryears,whilemediumdutytruckmufflersincertainvocationalapplicationsmaybereplacedasoftenaseverytwoyears.TheNelsonGlobalProductsmufflerwarrantyisthebestintheindustry.Pleasecontactusforwarrantydetails.Chromeplatedexhaustsystemproductsarewarranted,aswell,againstpeelingandblisteringwithinthetwelvemonthwarrantyperiod,beginningonfinalsaledatetotheend-userowner.Note: This warranty does not cover exhaust system

parts that rust out or are blown out by backfire or other faulty conditions nor exhaust system products damaged or destroyed resulting from incorrect installation, application or operation.

Study Questions 1. Therearesomeverystringentlocalregulations

forschoolbusexhaustsystems,andyoumaybefacedwithallofthefollowingrequirementsexcept:(Reference,pg.11)

a. Horizontalapplicationb. Atotallyleakfreesystemc. Verticalapplicationd. Rearexit

2. Dentsorcrushedportionsofanytubing(elbows,stacksorpipes)createexhaustflowrestrictionandsignificantlyincreasebackpressure.Evenrelativelysmalldentswillcause:(Reference,pg.12)

a. Decreasedfueleconomyandincreasedturbowear

b. Decreasedbearingwearc. Aslowleakd. Excessivesootbuildup

3. Theexhaustsystemcomponentthatismostcommonlyreplacedisthemuffler.Accordingtostatistics,heavydutymufflersarereplacedeverythreetofouryears,whilemediumdutytruckmufflersincertainvocationalapplicationsmaybereplacedasoftenasevery_____years.(Reference,pg.12)

a. 2b. 3c. 4d. 5

Exhaust System Basics

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Let’sreviewtheextensivelineofNelsonGlobalProductsexhaustaccessoriesandrelateditems.

Stack Pipes

StraightStack

CurvedStack

Therearecurvedandstraightstackpipesinpopularlengths,availableinmirrorqualitychromeplated(partnumbersuffix“C”)andaluminizedsteel(partnumbersuffix“A”).Peoplewhoareseriousabouttheappearanceoftheirtruckgenerallybuychromestacks,whilealuminizedstacksarefunctionalandwillholdupforthelongerhaul.

Keepinmindthatwhilemanyofthecompetitivealternativesarecheaper,theyareoftenofextremelypoorquality.Thechromefinishesontheseinferiorproductstendtorustorpeelinarelativelyshorttimeduetopoormanufacturingprocesses.Mildsteelstacksandelbowsmaybelesscostlytobuy,butbecauseofshortservicelife,theycostmorepermilethanaluminizedsteelproducts.

NelsonGlobalProductsusesanexcellentnickelplated,chromefinishingprocess—andthatguaranteesthehighestquality.Sure,youcanbuycheaperalternatives,andtheymaylookgoodforashortperiodoftime.Simplyremindyourselfthatifyouinvestalittlemoreingoodquality,itisfarmorecosteffectiveinthelongrun.

Nelson Global Products Exhaust System Components

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Exhaust Clamps Anytimeamufflerorexhaustpipeisreplaced,therelatedclampsshouldalwaysbechanged.Heavydutyclampsaredesignedforfast,easyandaccurateinstallation,aswellasmaximumclampingforcewithoutcrushingpipes.Someofthemostwidelyusedoptionsinclude:

Wide Band ClampThistypeofclampminimizesexhaustsystemleaksandholes,protectingthedriverinthecabfromodorless,poisonousgaseswhichcanseepinfromthesystem.This

clampreducestheneedforweldingthepipeandmakesatightsealwithoutdamagingthepipediameter.Italsoworksforbuttandlapinstallationsusingeithersolid-to-solidtubingorflex-to-solidtubing.

Guillotine Clamp Thisclampisthemostcommonfasteningdeviceonpipesof2"(50.8mm)to6"(152.4mm)diameters.

V-Band ClampThistypeofclampconnectsthemanifoldorturbochargertotheexhaustsystemandisavailabletocoverthemajorityofengineapplicationsandsizes.

Flat Band Clamp Thistypeofclampisavailableineitherzincorchromeplatedin3"(76.2mm)to6"(152.4mm)pipediameters.

Rain Caps Ifyouhavestraightstacks,NelsonGlobalProductsoffersaselectionofaluminizedsteelorchromeraincaps,allfeaturingsingleboltmountingandheavydutyweldedassemblyforlonglife.NelsonGlobalProductsraincapsarealsoprecisionbalancedtokeeptherainout,protectthemufflerandexhaustsystemfromrustandgetridofcarbonresidueforgood.

Heat Guards and Grab Handles NelsonGlobalProductsheatguardsareavailableinbothaluminizedsteelandbrightstainlesssteelwithvariousdegreesofwrapandholepatterns—allengineeredtoprotectthedriverandothersfromahotmuffler.NelsonGlobalProductscanevenpersonalizeheatshieldsandmufflerswithacustompunchedpattern,nameorlogorightintothesteel.

Auniversalchromeplatedgrabhandleisalsoavailabletomakeiteasiertoenterthecab.

Nelson Global Products Exhaust System Components

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Flexible Tubing Likemanyofitscompetitors,NelsonGlobalProductsoffersgalvanized flexforthosewhoneedaproductataverylowprice.

NelsonGlobalProductsalsooffersstainless steel flexforfirstclass,longlifeapplication.Becauseofthehighpriceofstainlesssteel,thecompanynowoffersalonglife aluminized steel flex.This

aluminizedtubingprovidesaqualityoptionwithaffordablepricing,muchclosertothatofthegalvanizedtubingthantostainlesssteelflexhose.

Characteristics Of Nelson Global Products Flex Galvanized flex hose willwithstanduptoapproximately600°F(316°C)beforeheatbreakdownofthecoatingstarts.Atthispoint,thematerialbeginstodegradeandrustbeginstoform.

Ontheotherhand,aluminized coatingwillwithstandconditionsover1200°F(649°C)beforethealuminumcoatingstartstosoften.

Ofcourse,stainless steel flex tubingisdesignedtowithstandhightemperatures,suchasthosefoundingasolineengineapplications.Itsonlydrawbackisatendencytoturndifferentcolorswhenexposedtoveryhightemperatures,acosmeticchangewithnoeffectonperformance.

Measuring Flex Whenitcomestomeasuringflextubing,thereisacertainamountofdisagreement.Differentpeoplemeasureitindifferentways;sinceit’ssoldbythefoot,disputescancropupabouthowmuchwasshippedversuswhatwasordered.

Topreventanymisunderstandings,NelsonGlobalProductsrecommendsastandardmethodformeasuringflex.Sincethenaturallieofflexishalfwaybetweenfullyextendedandfullycompressed,NelsonGlobalProductsflexiscurrentlysuppliedinfullyextendedlengthsplus2"(50.8mm)extraon10foot(3.05m)lengths,or6"(152.4mm)extraon25foot(7.62m)lengths.

To properly measure flex,coilthetubinginastightaradiusaspossible.Now,measuretheoutsideparameterofthecoil;thiswillgivetheoverall,fullyextendedlengthofthesectionofflex.

Sinceflexisgenerallysoldinextendedlengthsthroughoutthemarketplace,it’simportantthataccuratemeasurementsbeprovidedbyallcompetitorsanddistributors.Remember: the extended length is generally 1.2 times the compressed length. Thisisonlyanestimateandshouldnotbeusedasanaccurateformofmeasurement.

Nelson Global Products Exhaust System Components

Length

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Cutting Flex Thereareseveralwaystocutflextubing.Themethodmostacceptedbytheindustryistotackweldtheflexonbothsidesofthecutbeforeactuallycutting.Withthisdone,thereisnowayfortheflextounravelafteritiscut.Thiswillalsokeepthediameteroftheflexwithintolerancessothatitcannotbecomeuncoiledoncetheparthasbeencut.

Thebestandeasiestmethodforcuttingflexisplasma cutting,which:

• Leavesasmoothendwithnoburrs

• Requireslittleornotrimming

• Doesnotrequirehardclamping(whichcandeformtheflexribs)

Theband saw(orhacksaw)cuttingmethodiscommonlyusedtocutflextoproperlengths.Thismethod:

• Leavesveryroughedges

• Requirestheremovalofsharpburrsbeforeuse

• Requiresadditionalworkontheendstobesuretheflexdoesnotgrowindiameter

Anothermethod,notoftenused,reliesonapipe cutter.Thistypeofflexcuttingis:

• Notpopularorwidelyaccepted

• Needsseveraldifferentsizesofcutters,dependingonthevarietyofdiametersofflex

• Leavessharpedgeswhichrequiretrimming

Study Questions

1. Thebestandeasiestmethodforcuttingflexis_______________.Thismethodleavesasmoothendwithnoburrs,requireslittleornotrimminganddoesn’trequirehardclamping,either.(Reference,pg.16)

a. Theuseofapipecutterb. Theuseofahacksawc. Bandsawcuttingd. Plasmacutting

2. Flextubingisgenerallysoldinextendedlengthsthroughoutthemarketplace,soit’simportanttogetaccurateandconsistentmeasurements.Theextendedlengthisgenerallyhowmanytimesthecompressedlength?(Reference,pg.15)

a. 1.5b. 1.2c. 3d. 2

3. NelsonGlobalProductsprovidesthreedifferentflexibletubingoptions—andarangeofqualityandpricing—tomeeteveryneedandapplication.Theseflexibletubingoptionsincludeallofthefollowingexcept:(Reference,pg.15)

a. Galvanizedb. Aluminizedcoatingc. Chromed. Stainlesssteel

Nelson Global Products Exhaust System Components

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Aluminized Steel Thetopgradesteelusedduringproductionofmufflersandexhaustsystemproductsisspeciallytreated—oraluminized—toresistcorrosion,eveninhightemperatureconditions.

Back Pressure Exhaustgasesmustbepushedthroughtheexhaustsystembytheengine.Theamountofforceittakestodothisiscalledexhaustbackpressure.Excessivebackpressurecausespoorengineperformance,lossofhorsepower,poorfueleconomyandhighengineoperatingtemperatures.

Flat Band Clamp Aheavydutyexhaustsystemclamp,availableeitherzincorchromeplatedin3"(76.2mm)to6"(152.4mm)pipediameters.

Guillotine Clamp Aheavydutyexhaustsystemclampthatformsasolidsealonpipesof2"(50.8mm)to6"(152.4mm)diameters.

Horizontal Application Withtheindustryfocusonaerodynamics,ithasbecomemorepopulartouseahorizontalconfigurationthatputstheexhaustsystemunderneaththetractor/trailer.Insomecases,theresimplymaynotberoombetweenatractorandtheboxinastraighttrucktoinstallaverticalexhaustsystem.Ahorizontalconfigurationisthentheidealsolution.

Muffler Akeycomponentoftheexhaustsystemwhichreducesthenoisemadebytheengineduringcombustionandexhaust.Attachedtotheexhaustpipeorelbow,themufflerprovidesachamberwhereexhaustgasesexpand,coolanddissipate—whichdecreasesthenoise.

Strap Clamp Aheavydutyexhaustsystemclampthatminimizesexhaustsystemleaksandholes,protectingthedriverinthecabfromodorless,poisonousgaseswhichcanseepinfromthesystem.Thistypeofclampreducestheneedforweldingthepipeandmakesatightsealwithoutdamagingthepipediameter.Italsoworksforbuttandlapinstallationsusingeithersolid-to-solidtubingorflex-to-solidtubing.

Vertical Application Withaverticalapplication,themufflerisboltedtoamaststructureofftheframerail(ortothebackofthecab).Somepreferthisverticalstacksystemasawaytogetanyobjectionableexhaustodorupawayfromgroundlevel.However,thereisnoregulationortechnicalrequirementforoneconfigurationovertheother;thischoiceissimplyamatterofpersonalpreference.

Glossary Of Terms

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ThisFinalReviewExerciseisagoodwaytoreviewandpracticeusingtheinformationfoundinthismanual.Bycompletingallofthemultiplechoicequestions,youwilldiscoverwhichareasyouunderstandbestandwhichtopicsneedalittlemoreattention.Onceyoufeelconfidentwithyouranswers,you’llbereadytodiscussNelsonGlobalProductsmufflersandexhaustsystemcomponents.YoucancheckyouranswersagainsttheAnswerKeyonpage9.

1. Oneofthemostimportant“rules”torememberwhenspecifyingreplacementpartsisthis:Alwaysreplacecomponentswithlikecomponents.Whyisthissoimportant?(Reference,pg.7)

a. ItisamandatoryrulingoftheFederalNoiseControlActof1972.

b. Thereislittledifferencebetweenmufflers.c. OEMspecifiedmufflersaretheonlylegal

applicationincertainstates.d. Mufflerscouldhavethesameexteriorsize

buthaveverydifferentinteriorconstructionandperformance.

2. Youmaypreferaverticalexhaustsystemasawaytogetanyobjectionableexhaustodorupawayfromgroundlevel.Withthistypeofverticalapplication,themufflermustbeboltedto:(Reference,pg.11)

a. Amaststructureofftheframerailortothebackofthecab.

b. Onlytothebackofthecab.c. Onlytoamaststructure.d. AWyeconnector.

3. Thefirstnationwideregulationontrucknoiserequiredtotaltrucknoiselevelstobelessthan86dBAmeasuredat50feet(15.24m)forspeedslessthan35mph(56.33km/h).Thisregulation,modifiedin1978andloweredtothecurrent80dBAnoiselevelin1988wasthe:(Reference,pg.4)

a. FederalNoiseControlActof1972b. DieselNoiseRegulationof1972c. TruckNoiseLevelControlActof1970d. FederalNoiseEmissionsActof1970

4. Therearesomeverystringentlocalregulationsforschoolbusexhaustsystems,andyoumaybefacedwithallofthefollowingrequirementsexcept:(Reference,pg.11)

a. Horizontalapplicationb. Atotallyleakfreesystemc. Verticalapplicationd. Rearexit

5. The________________clampreducestheneedforweldingthepipeandmakesatightsealwithoutdamagingthepipediameter.Thisclampwouldbeusedtominimizeexhaustsystemleaksandholes,andtoprotectthedriverinthecabfromodorless,poisonousgaseswhichcanseepinfromthesystem.Itisthe:(Reference,pg.14)

a. Guillotineclampb. Strapclampc. V-bandclampd. Flatbandclamp

6. Theaverageexhaustsystemtemperatureofgasanddieselapplicationsrangefrom800°F(427°C)to1,400°F(760°C).NelsonGlobalProductsaluminizedsteelnotonlyresistsoxidationmuchlongerthanunprotectedmildsteel,itholdsitsstrengthcharacteristicsupto:(Reference,pg.10)

a. 800°F(427°C)b. 1,000°F(538°C)c. 1,300°F(704°C)d. 1,400°F(760°C)

7. Flextubingistypicallysoldinextendedlengthsthroughoutthemarketplace,soit’simportanttogetaccurateandconsistentmeasurements.Theextendedlengthisgenerallyhowmanytimesthecompressedlength?(Reference,pg.15)

a. b. 1.5c. 1.2d. 3e. 2

Final Review Exercise

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8. Exhaustgasesmustbepushedthroughtheexhaustsystembytheengine.Theamountofforceittakestodothisiscalled_______________.Toomuchcausespoorengineperformance,lossofhorsepower,poorfueleconomyandhighengineoperatingtemperatures.(Reference,pg.7)

a. Exhaustpressureb. Backpressurec. Resonationd. Wyeforce

9. NelsonGlobalProductsprovidesthreedifferentflexibletubingoptions—inarangeofqualityandpricing—tomeeteveryneedandapplication.Theseflexibletubingoptionsincludeallofthefollowingexcept:(Reference,pg.15)

a. Galvanizedb. Aluminizedcoatingc. Stainlesssteeld. Chrome

10. TherearenumerousdesignfeaturesthatmakeNelsonGlobalProductsmufflerstoprate.Perhapsthemostimportantisthefloatingbaffledesign,patentedbyNelsonGlobalProducts,thatreliesonaseriesofsmallpartitions(orbaffles)toimpedesoundwaveswithmaximumnoisereductionwithminimumbackpressure.AllofthefollowingarealsokeyadvantagesofNelsonGlobalProductsmufflersexcept:(Reference,pg.9)

a. Exclusivebackpressurevalveb. 500,000mile(804,672km)warrantyc. OEapprovedd. Aluminizedsteelconstruction

Final Review Exercise

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