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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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