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Engine AftermarketExhaust WarrantyOVERVIEWThe information below is the exhaust portion of our Engine AftermarketFiltration & Exhaust Warranty Document: F110064Warranty CoverageDonaldson warrants its Aftermarket products againstfailure due to defects in materials and workmanshipfor the period specified under Terms and Conditionsfor the particular product. Donaldson’s obligationunder this warranty covers replacing the failedproduct, including transportation charges, only.If the Donaldson product failure is the sole anddirect cause of damage to the equipment on whichthe product was properly installed, Donaldsonwill reimburse reasonable costs to restore theequipment to the condition it was in immediatelybefore the failure. This warranty does not coverfailure due to misapplication, misuse, abuse,neglect, rust through and corrosion (mufflers),improper installation, improper service practices ornon-Donaldson approved modifications.Engine and equipment manufacturers warrantiesremain in effect when Donaldson products are used.NotificationDonaldson must be notified in writing of any claimscovered by this warranty within one year of the dateof failure. Donaldson, at its discretion, will eitherphysically visit the site where the alleged failure hasbeen found; or, request that all parts (Donaldson andother relevant parts) be shipped prepaid to its GeneralOffice, in care of the Product Lab or as otherwisespecified.Terms and ConditionsWarranty coverage begins on the date and mileagethe product is purchased by the user and expireswhen the specified number of years or miles haspassed, whichever occurs first.The length of warranty for replacement productsprovided under warranty coverage is the balance ofthe warranty period remaining on the product beingreplaced.Warranty Length by Product TypeExhaust ProductsWarranty from Date of Delivery to UserDiesel MufflersVertical InstallationHorizontal Installation4 years or 500,000 miles (800,000 km)3 years or 500,000 miles (800,000 km)Gas Mufflers1 yearSilent Partner Exhaust SilencerStainless SteelAluminized SteelExhaust AccessoriesChrome Parts (peeling and blistering only)Flex PipeLong-Life Flex Pipedonaldson.com8 years or 1,000,000 miles (1,6000,000 km)4 years or 500,000 miles (800,000 km)1 year1 year or 100,000 miles (160,000 km)90 days1 year or 120,000 miles (200,000 km); on-highway use onlyExhaust Product Guide 7

ShoptalkGeneral Exhaust Facts, Maintenance Tips and Product FeaturesSHOPTALKSection IndexPurpose of an Exhaust System. 10Muffler Design & Performance . 10Exhaust Product Materials. 12Noise Sources. 13Reduce Exhaust Noise. 13Familiar Sounds on the dBA Noise Scale. 13Noise Rules of Thumb. 13E.P.A. Truck Noise Regulations. 14Emissions Devices & Acoustic Silencing. 14Diesel Particulate Matter (PM) Allowedper Horsepower-Hour (soot vials). 15Emissions Mandates & Timing. 15SealClamp Installation InstructionsFlat Band Style. 16Stepped Preformed Style. 17Cutting & Installation Instructionsfor Flex Tubing. 18Donaldson & Industry Acronyms. 19Engine Brake & Exhaust Silencer. 19Terms & Definitions. 20donaldson.comExhaust Product Guide 9

ShoptalkSHOPTALKGeneral Exhaust Facts, Maintenance Tips and Product FeaturesPurpose of an Exhaust SystemExhaust system design specifications are typically defined by the OEs. They are looking for a solution that can redirect engineexhaust, reduce exhaust noise and most recently, reduce emissions (hydrocarbons, carbon monoxide, soluble organic fraction (SOF)).Diesel engines are a reliable and efficient power source for vehicle and equipment manufacturers. Governmental regulations acrossthe globe are driving diesel engine users to consider buying new vehicles to meet the new emissions regulations.Muffler Design & PerformanceDonaldson mufflers are designed and tested with specific focuson three performance variables: attenuation, backpressure andstructural.AttenuationFor exhaust systems, attenuation refers to the reduction insound level measured between an engine without a mufflerand the same engine with a muffler. This sound level is typicallymeasured in a decibel scale (dBAs). Traditional mufflers usetubes, baffles, and expansion chambers and insulation to helpcontrol noise. Newer applications include emissions reductiondevices installed in the exhaust system. Many of the devicesalso provide the needed noise attenuation either in part or intotal.Sound quality is an additional noise characteristic that isimportant to the end user. An example of a sound qualityconcern is the sound of fingernails on a chalk board – thisscreeching sound makes people wince, yet the measured soundlevel would not be significant. A low throaty rumble may seemeven quiet (and almost desirable) but may be amplified andbecome annoying if it reverberates within the operator’s cabin.Engine manufacturers generally expect a reduction in engineexhaust sound level of 15-25 dBA. The overall noise level of avehicle or piece of stationary equipment is the actual regulatedvalue. The overall noise level is typically measured whiledriving past a microphone at a specific speed and distance.Maximum noise levels in the U.S. are regulated by the U.S. EPA(Environmental Protection Agency).10 Exhaust Product Guidedonaldson.com

ShoptalkGeneral Exhaust Facts, Maintenance Tips and Product FeaturesReactive silencingWhat's important: the ratio of the body diameter to the tube.BackpressureA key performance factorin selecting the propermuffler is backpressure. Forthe most efficient engineperformance it is important toapply a muffler that minimizesbackpressure.SHOPTALKHeavy-duty mufflers typically employ one ofthree sound reduction techniques including:Reduced NoiseBetter Sound AttenuationHigherBackpressureLowerMore PowerResistive silencingExhaust flow is forced through a small area. It removes energyto reduce noise level.Backpressure is the forceBetter Fuel Economynecessary to flow gassesthrough the Exhaust system, orthe resistance to exhaust flow. System considerations includefriction and momentum effects - expansion / contraction /elbows, and velocity head loss at outlet.To minimize backpressure, long tube lengths, small tubediameters and sudden contractions should be avoided.Absorptive silencingTransforms wave energy into thermal energy. Uses acousticpacking (or wrap) just inside the outer shell of the muffler.Backpressure can reduce horsepower and fuel economy. Forexample, turbocharged diesel engines loose about 0.5% inhorsepower and fuel economy per inch Hg backpressure. Tohelp you minimize backpressure, our selection guide providesexhaust flow ratings at 1", 2" and 3" Hg (mercury).Conversion: 1.0" Hg 13.6" H20Our muffler spec'ing section outlines the steps you need to takefor proper muffler selection.StructuralAnother performance factor is the structural durability of thesystem configuration. Position, mounting support, weight andthe type of material that the unit is made from are the key subcomponents of system structure.For example, the original OE stanchion or chassis mountingcomponents are adequate for a replacement muffler. If youapply a heavier muffler, like one with an emissions device inside,it’s critical to upgrade the hangers, brackets and stanchion withmore robust and heavier components. Most exhaust systemproblems encountered by Donaldson field service are due toimproper bracketing and/or use of clamps – not the muffler ormuffler construction.donaldson.comExhaust Product Guide 11

ShoptalkSHOPTALKGeneral Exhaust Facts, Maintenance Tips and Product FeaturesExhaust Product MaterialsThere are a number of materials found in diesel exhaustapplications. Some of the materials are appropriatefor heavy-duty applications and have the mechanicalproperties to provide good service life.Since materials vary in strength, corrosion resistance,and price, a particular material may be preferred inindividual applications and components. Some of themost common materials, their qualities and their typicaluses are listed in the following table.Materials*Aluminized MildSteelStainless Steel(with and withoutaluminized coating)Used inMufflersExhaust ComponentsFlexible TubingMufflersExhaust ComponentsEmissions ProductsQualities- Good CorrosionResistance- Stronger- Excellent CorrosionResistance- Temperature Limit1500 FChromeAccessories- Bright Mirror FinishGalvanizedFlexible Tubing- Low Material Cost- Temperature Limit600 FCold RolledAccessories- Poor CorrosionResistance- Low CostAluminized steel is the preferred material for traditionaldiesel exhaust applications. Aluminized steel is a lowcarbon steel with a thin layer of aluminum alloyedto the surface. The aluminum provides a barrier forprotection of the base material. Aluminized steelparts have an ultimate service temperature of 1500 Fwith a continuous duty temperature limit of 1000 F.This material closely matches the expected servicetemperatures of diesel engine applications and hasexcellent corrosion resistance to acidic diesel exhaustgases. Aluminized steel parts provide good field life at areasonable cost. Paint adhesion issues could occur withaluminized steel parts if operating conditions producecontinued surface temperatures that exceed 850 F.Series 400 stainless steels are used for many extendedservice life diesel applications and often in gasolineapplications due to their higher operating temperatures.This material family provides slightly better strength atexhaust system temperatures than aluminized steel.than aluminized but exhibits cosmetic problems atexhaust system temperature. At first exposure tohigh temperature it discolors. Over time it developsa nondestructive coating of surface rust. After anextended time in the field a 409 product will displayexternal discoloration and look worse than a similar partmade from aluminized steel, but will last much longer.Another choice is 409 stainless steel with an aluminumcoating. Aluminized 409 is used on diesel catalyticconverter mufflers due to its excellent high temperatureresistance and the corrosion protection of thealuminized coating. Aluminized 409 is found primarilyon emission products or high temperature gasolineapplications.Series 300 stainless steels are also utilized in exhaustsystems. The most common material is Type 304. Thismaterial has excellent corrosion resistance and verygood high temperature strength and is used in somemuffler applications where very high stresses occur.This is a premium material and is also used in manygasoline applications. The most prevalent use of thematerial in heavy-duty diesel applications is for flex pipe.Flex pipe produced from light gauge 304 stainless steelis an excellent choice considering all the factors of cost,durability and service life.Often chrome plated cold rolled steel parts are foundon exhaust system parts. This material is a reasonablechoice for cosmetic applications where a bright mirrorfinish is desired. Corrosion from the inside of the productcan still occur. Chrome parts may be very challenging toproduce. It is important to produce the parts with a highlevel of quality because surface irregularities are veryvisible to the end user.An alternate choice for chrome parts is bright annealedstainless steel. This material provides a bright mirror-likefinish with excellent exhaust service life. Bright stainlesssteel is typically used for muffler heat shields andgenerally is an expensive material choice.Type 409 is the most common 400 series stainless steelused in exhaust applications. Type 409 is stronger12 Exhaust Product Guidedonaldson.com

ShoptalkGeneral Exhaust Facts, Maintenance Tips and Product FeaturesExhaustSystemRules of ThumbFan Noise5124Air Intake3SHOPTALKFive Major Sources of Noise in TrucksCombining Two Equal NoiseSources Increases SoundsLevel by 3 dBATwo equal noise sources combine tocreate a sound level 3 dBA greaterthan either source.83dBA83dBAMechanical NoiseTiresEasy Maintenance Tips Reduce Exhaust Noise1Check the exhaust tubing. Repair or replace worn or leaking components.2Make sure your exhaust system is properly supported.3Installing a resonator or wye connector muffler is an economical way toreduce noise.4Modify a single exhaust system to a dual.5Check stack and tailpipe position. A straight stack will be quieter than acurved stack on vertical exhaust systems. Turn your horizontal tailpipestoward the center of the road.86dBATwice the Loudness is a10 dBA IncreaseThe increases are not linear!Increasing noise by 10 dB soundstwice as loud.Familiar Sounds on the dBA Noise ScaleOther examples of sound levels: 70 dB Traffic jam; 90 dB Heavymachinery, 130 dB Jet engine at 10 meters.Siren (100 feet)Automobile Horn (3 feet)Threshold of Pain140110Commercial Airliner (inside)Snowmobile (50 fet)Conversation (3 feet)100706050Soft Whisper (4 feet)Chain Saw (50 feet)Motor Cycle (50 feet)9080Over Road Truck(50 feet)Business Office20donaldson.com70dBASound Pressure LevelChanges With DistanceDoubling the distance to a noisesource decreases its sound level by6 dB. Halving the distance to a noisesource increases its sound level by6 dB.6 dBA Decrease4010 Feet86 dBA30Threshold of HearingdBAJet Plane (50 feet)13012080100dBA20 Feet80 dBARecording Studio6 dBA IncreaseExhaust Product Guide 13

ShoptalkSHOPTALKGeneral Exhaust Facts, Maintenance Tips and Product FeaturesU.S. EPA Truck Noise Regulationswww.epa.govIn the past, the EnvironmentalProtection Agency (EPA) coordinatedall federal noise control activitiesthrough its Office of Noise Abatementand Control. However, in 1981, theAdministration at that time concludedthat noise issues were best handled atthe State or local government level. Asa result, the EPA phased out the office’sfunding in 1982 as part of a shift infederal noise control policy to transferthe primary responsibility of regulatingnoise to state and local governments.However, the Noise Control Act of1972 and the Quiet Communities Act of1978 were not rescinded by Congressand remain in effect today, althoughessentially unfunded.Noise Standards*Interstate Truck 10,000 lb.Equal to or less than 35mpg 83 dBAGreater than 35mph 87 dBANew (first-fit) Truck 80 dBA*Trucks greater than 10,000 lbs. 40 CFR 202.20** Noise is measured at 50 feet (15.2 m) from the centerline of the lane of travelInterstate Motor Carrier NoiseThe Federal Highway Administration’s Office ofMotor Carrier and Highway Safety Web site includesinformation on the Interstate Motor Carrier NoiseEmission Compliance Regulations from the Code ofFederal Regulations (49 CFR 325).Subparts for compliance of the interstate motor carriernoise emission s/administration/fmcsr/fmcsrguidedetails.aspx?rule toc 730§ion toc 730PartRegulationSubpart A General ProvisionsSubpart B Administrative provisionsSubpart C InstrumentationSubpart D Measurement of noise emissions; highway operationsSubpart E Measurement of noise emissions; stationary testSubpart F Correction factorsSubpart G Exhaust systems and tiresEmissions Devices & Acoustic SilencingVarious emissions reduction technologies are appliedto exhaust systems to meet current emissionsstandards. The additional components can significantlychange or eliminate the traditional acoustic silencingcomponents common in older muffler designs.Depending on the application, emissions reductiondevices may totally eliminate the need for furthersound control and for others, minimal acousticsilencing may be required. The sound attenuation ofemissions devices varies depending on the filteringsubstrates an

Donaldson exhaust systems are original equipment on most pre-2007 medium- and heavy-duty trucks manufactured in North America. Donaldson engineers work with many OE truck and off-road equipment manufacturers to design and build quality exhaust systems to meet specific performance requirements. Donaldson