Exhaust Product Guide

Our innovative products are solving complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment. Donaldson has the technical expertise, superior customer support and vast network of locations around the world to meet your toughest filtration needs - from initial system design through replacement products.

Exhaust Product Guide for Medium- & Heavy-duty Vehicles and Equipment

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This publication contains a wide selection of standard mufflers and exhaust components for diesel-powered vehicles and equipment that operate in a variety of conditions. For assistance, contact Donaldson or your local Donaldson distributor.

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TABLE OF CONTENTS MEDIUM- AND HEAVY-DUTY EXHAUST PRODUCTS CATALOG NO. F116080

Our innovative products solve complex filtration and exhaust system challenges that improve people’s lives, enhance engine and equipment performance and protect our environment. Donaldson has the technical expertise, superior customer support and vast network of locations around the world to meet your toughest needs – from initial system design through replacement products.

This publication contains a wide selection of standard exhaust components for both original equipment manufacturers and replacement parts for existing diesel-powered vehicles and equipment that operate in a variety of conditions. For assistance with muffler or accessory selection, contact your local Donaldson distributor or dealer.

Overview ............................................. 2 Exhaust Product Line.....................................2 Expanded Catalog Content and Where to Buy.........................................4 History ...........................................................5 Diesel Retrofit Emissions Solutions...............6 Engine Exhaust Flow & Airflow Calculations .7 Engine Aftermarket Exhaust Warranty...........8 Accessories.......................................... 9 Exhaust System Components ..................... 10 Common System Configurations.................11 Exhaust Joint/Connections .......................... 12 Exhaust Clamps...................................... 13-17 Heat Sleeves & Heat Wraps ........................18 Flex Tubing & Cut to Length Flex ............ 18-19 Sliding clamps 2nd generation.....................20 V-Band Clamps for Flanged Connections.....21 Flared Connectors & Adapters.....................22 Reducers/Expanders....................................23 Tilt Cab Ball & Cone Connectors .................24 Y or Wye Adapter Pipe.................................24 Splitter Tee Adapter......................................24 Stack Caps ................................................... 25 Universal Swivel Hanger..............................25 Universal Mounting Bracket ........................25 Pipe Hangers ...............................................25 Universal Pipe Guards & Clamps.................26 Elbows & Bent Tubes..............................26-29 Straight Tubing & Stack Pipes .................30-32 Tailpipes .......................................................32 Spark Arrestors ............................................33 Muffler Guards & Accessories.....................34 Muffler Hangers...........................................34 Heavy-Duty Muffler Mounting Straps.....34-36 Heavy-Duty Hangers Grab Handles, Manifold Tube/Flange & Threaded Adapters ......................................37 Exhaust Ejectors & Check Valves ...........38-39 DPF Pulse Cleaner..................................40-41 DPF Thermal regenerator........................42-43

Muffler Selection & Specifications.. 45 Attenuation & Backpressure By Muffler Style & Inlet/Outlet Size.............47 Muffler Specifications by Part Number........53 Muffler Specifications by Style & Inlet ........66 Shoptalk ............................................ 67 Shoptalk - Free Subscription! ....................67 Purpose of an Exhaust System....................68 Muffler Design & Performance ...................68 Exhaust Product Materials...........................69 Noise Sources .............................................70 European Noise Legislation Off Road..........71 Rules of Thumb............................................72 Emissions Devices & Acoustic Silencing.....72 Familiar Sounds on the dBA Noise Scale.....72 Emissions Mandates & Timing ....................73 Diesel Particulate Matter (PM) Allowed per Horsepower-Hour (soot vials) ............73 Cutting & Installation Instructions for Flex Tubing.......................................... 74 Donaldson & Industry Acronyms.................75 Engine Brake & Exhaust Silencer ................75 SealClamp™ Installation Instructions .....76-77 Terms & Definitions .....................................78 Part number index .......................................79

Improve

Enhance

Protect

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Page Header - Left Page Sub Header - Left NOT USING Exhaust Product Line .VGnFST $IBSBDUFSJTUJDT3FQMBDFNFOUT

Donaldson Mufflers 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 based on the specific performance.

Features and Benefits of Donaldson Mufflers Low Backpressure Better fuel economy and efficient engine performance Aluminized Steel Delivers long service life and is corrosion resistant Lightweight Construction Minimizes stress and vibration on mounting system High Temperature Paint Available on select product. Paint adds corrosion resistance and enhanced finish

Truck Mufflers for Every Budget

BEST 1BSU/P..

t NJMMJPONJMFXBSSBOUZPO. – stainless steel Silent Partner ™ t NJMFXBSSBOUZPO.o aluminized steel Silent Partner t 4VQFSJPSBDPVTUJDQFSGPSNBODFo specifically addresses engine brake noise by silencing engine brake “bark” t .%POBMETPONVGnFS t .FFUTBMM0&.CBDLQSFTTVSF strength and life requirements t &YIBVTUOPJTFMFWFMJT E# " RVJFUFSUIBO .NVGnFS t 5IF.JTUIFNPTUDPNNPO NPTUQPQVMBSTFSWJDFNVGnFSJOUIF industry t -PXCBDLQSFTTVSFQSPWJEFTHPPE fuel economy and efficient engine performance

BETTER 1BSU/P.

GOOD 1BSU/P.

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Internal Heat & Noise

Outer Wrap

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Page Header - Right Page Sub Header - Right NOT USING Exhaust Product Line &YIBVTU$POmHVSBUJPOT .VGnFS4UZMFT .BUFSJBMT"DDFTTPSJFT

Exhaust System Configurations

Exhaust Product Materials A number of different materials are found in exhaust systems. Often different options are available for use in BTJOHMFBQQMJDBUJPO4JODFNBUFSJBMTWBSZJOTUSFOHUI DPSSPTJPOSFTJTUBODF BOEQSJDF BQBSUJDVMBSNBUFSJBMNBZ be preferred in individual applications and components. 4PNFPGUIFNPTUDPNNPONBUFSJBMT UIFJSRVBMJUJFT BOE their typical uses are listed in the following table. Materials* Used in Qualities Aluminized Mild Steel .VGnFST (PPE$PSSPTJPO3FTJTUBODF &YIBVTU$PNQPOFOUT Stainless Steel Flexible Tubing

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Style 2A Dual End Inlet / End Outlet

Emissions Products

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Accessories

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New & Expanded Catalog Content Expanded Catalog Content & Where to Buy

This edition of the Donaldson exhaust catalog includes the following additional information:

New Heavy-Duty Accessories Newer and/or retrofit emissions systems weigh considerably more than the traditional OE exhaust system and require new mounting hardware to accommodate the extra weight. Our more popular heavy-duty brackets and clamps have been added.

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$SPTT3FGFSFODF $PNQBSFEUPPVSQSFWJPVTQVCMJDBUJPO UIJTTFDUJPOJODMVEFIVOESFETPGOFXDSPTTSFGFSFODFT8FEP encourage you to use the Donaldson on-line cross reference for the latest information. Shoptalk Section Shoptalk is all about sharing helpful information to become more informed about Donaldson exhaust products and systems. This section includes installation tips for and fact sheets for many exhaust/ emissions products and technologies.

WhereTo Buy Donaldson Products? Donaldson products are available through a variety of distribution PVUMFUT0&EFBMFST JOEFQFOEFOU warehouse distributors and exhaust-only distributors. Each of these distribution channels have their unique methods of servicing your needs to meet your business requirements. To find the closest outlet in your SFHJPO WJTJUXXXEPOBMETPOmMUFST com. Look in the Where to Buy section of our web site.

Confused About Which Exhaust Clamp To Select or What Clamp Should be Used?

Depending on your exhaust joint and XIBUZPVhSFDPOOFDUJOHUP JUhTOPUBMXBZT so easy to determine which one of our exhaust clamps is best for your needs. Take a look at this new information on QBHFPGPVSBDDFTTPSJFTTFDUJPOUIF next time you need a replacement clamp.

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History of Innovation

From Silencing to Emissions Reduction

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When exhaust was about silencing -- we led the way! 'SBOL%POBMETPOTPMEFOPVHINVGnFSTJOUPPQFOPVS mSTUFYIBVTUNBOVGBDUVSJOHGBDJMJUZJO(SJOOFMM *PXBJO *OUIFT TPVOENFUFSTXFSFVTFEUPNFBTVSFOPJTF MFWFMT TFFJNBHFPOSJHIU %POBMETPOJTPOFPGUIFmSTU manufacturers to introduce the use of aluminized steel in exhaust systems.

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%POBMETPOGPSNTBHSPVQEFEJDBUFEUPFNJTTJPOTSFEVDUJPOFGGPSUTGPS diesel engines; begins retrofit projects; Spiracle™ crankcase filtration introduced to eliminate emissions from open crankcase vents. Mass QSPEVDUJPOPG$$.TGPSPOSPBE0&TCFHJOT 'JSTUPGNBOZ$"3#BOE&1"WFSJmDBUJPOTGPS%POBMETPOSFUSPmU emissions solutions; first company to verify tailpipe and crankcase TPMVUJPO QBUFOUFE %POBMETPOFYQBOETFYIBVTUNBOVGBDUVSJOHJO"HVBTDBMJFOUFT .FYJDP FYIBVTUTZTUFNOPJTFBOEUIFFYUFSJPSCPEZUFNQFSBUVSF%POBMETPO4FBM$MBNQ band-style exhaust clamp launched into the marketplace. Donaldson expands UP+BQBO*O 64OPJTFSFHVMBUJPOTXFOUJOUPFGGFDUGPSPOSPBEWFIJDMFTo %POBMETPOPGGFSTBNVGnFSMJOFUIBUXBTFGGFDUJWFBUOPJTFSFEVDUJPOXJUIPVUMPTT of horsepower. *O %POBMETPOPQFOTBOFXUFDIOJDBMDFOUFS5IFDFOUFSJODMVEFEUXP BOFDIPJDDIBNCFSTXIJDIFYQBOEFEPVSUFDIOJDBMDBQBCJMJUJFT.VGnFSTNFFU 64&1"USVDLOPJTFSFHVMBUJPOT TPOJDDIPLFTBOEnPBUJOHCBGnFT When engine manufacturers needed help to meet the first U.S. &NJTTJPOTSFHVMBUJPOT JOOPWBUJPOTDPOUJOVFE*OUIFFBSMZT XF QJPOFFSFEUIFEFTJHOPGJOUFHSBUFEDBUBMZUJDDPOWFSUFSNVGnFSTBOE diesel particulate solutions for three major U.S. engine and truck NBOVGBDUVSFST*OUIFMBUFT 4JMFOU1BSUOFSXBTUIFmSTUNVGnFS that effectively reduced engine brake noise without loss of power PSGVFMFDPOPNZ%VSJOHUIJTEFDBEF %POBMETPOFYQBOETFYIBVTU NBOVGBDUVSJOHJO&VSPQF 'SBODF .FYJDP (VBEBMBKBSB BOEUIF6OJUFE 4UBUFT "MBCBNB

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2000s

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2004 Donaldson upgrades and expands heavy-duty engine test cell capabilities; U.S. MSHA BDDFQUT%POBMETPOIJHIUFNQFYIBVTUmMUFS/FXXFCCBTFE&NJTTJPOT3FTPVSDF$FOUFS XXXEPOBMETPODPNFOFSD FTUBCMJTIFE %1'$MFBOJOH4ZTUFNBOE%.'.VGnFSMBVODIFEGPSFNJTTJPOTSFUSPmUNBSLFU%POBMETPO JOUSPEVDFTBOBDUJWF TNBSU%1'FNJTTJPOTTPMVUJPOGPSUIFNPTUEJGmDVMUEVUZDZDMFTMPX UFNQFSBUVSF USBOTJFOUBOEFYUFOEFEJEMJOH %POBMETPOFYQBOET&VSPQFBOFNJTTJPOTTUBGGBOE.FYJDPFYIBVTUNBOVGBDUVSJOHUP .POUFSSFZ%POBMETPOJNQSPWFT4UFQQFE4FBM$MBNQ 2007 Donaldson expands OE emissions support with production of active and passive exhaust aftertreatment systems to meet U.S. EPA 2007 on-road emissions regulations. %POBMETPOQSPEVDFTVSFBBOEOPOVSFBCBTFE/0YSFEVDUJPOTZTUFNTGPS0&BOE retrofit for in-use vehicles.

Acronym Reference: See Shoptalk Section

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Diesel Retrofit Emissions Solutions www.donaldson.com/emissions

Governmental regulations across the globe are being implemented that reduce diesel emissions. These regulations affect both OE manufacturers and end users. Donaldson works with both OE NBOVGBDUVSFSTBOEnFFUTUPEFTJHOJOOPWBUJWF DVTUPNJ[FETPMVUJPOT 4FF4IPQUBMLTFDUJPOGPS%JFTFM1.MJNJUTBOEHMPCBMFNJTTJPOT SFHVMBUJPOT *OPSEFSUPNFFUSFUSPmUFNJTTJPOTSFHVMBUJPOT EJFTFMQPXFSFEWFIJDMF owners around the world will be faced with major business decisions UPCFDPNFDPNQMJBOUXJUIDVSSFOUSFHVMBUJPOTDIPJDFTJODMVEFSFUSPmU SFGVFM SFCVJME SFQPXFSPSSFQMBDF 'PSPMEFSWFIJDMFTUIBUIBWFmWFPSNPSFZFBSTPGVTFGVMMJGFBWBJMBCMF nFFUPXOFSTBSFFMFDUJOHUPSFUSPmUUIFJSWFIJDMFTUPFYUFOEUIFMJGFPG their current equipment. Donaldson takes a “total system approach” to retrofit – delivering QBUFOUFETPMVUJPOTUIBUSFEVDFOPUKVTUXIBUDPNFTPVUPGZPVSUBJMQJQF we also offer a solution that eliminates emissions generated from the FOHJOFDSBOLDBTF 4QJSBDMFDSBOLDBTFmMUSBUJPOUFDIOPMPHZ %POBMETPOIBT$BMJGPSOJB"3#BOE64&1"WFSJmFETPMVUJPOT BO JOTUBMMBUJPOTFSWJDFOFUXPSL BOEMPDBM%POBMETPOSFQSFTFOUBUJWFTUIBU BSFSFBEZUPIFMQZPVTFMFDUUIFCFTUTPMVUJPOGPSZPVSnFFU Do you have questions about meeting retrofit emissions SFHVMBUJPOT We have a specialized team of emissions experts that can help determine your emission reduction targets and then specify the right %POBMETPOTPMVUJPO LFFQJOHJONJOESFHVMBUJPOT CVEHFUTBOEnFFUTJ[F

Choices for Diesel Retrofit Retrofit – new emission control devices on existing engines mMUFST DBUBMZTUT Refuel – cleaner diesel fuel 6-4% FNVMTJPOTPSBEEJUJWFT Rebuild – repair/upgrade key components or engine reprogramming Repower – put new or newer engine in existing equipment or chassis Replace – vehicle/equipment condition less than the value of new engine

Internet Resource: Emissions Resource Center

www.donaldsonoemfiltration.com/technologies/emission

Emissions Retrofit Products Retrofit solutions include

cost-effective and high efficiency tailpipe and Spiracle™ crankcase filtration technologies plus our %1'DMFBOJOHTZTUFN %1' pulse cleaner and DPF Thermal 3FHFOFSBUPS

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Engine Exhaust Flow Rate & Airflow Calculations

European Engine Flow Rate Calculation Formula : &YIBVTUnPXSBUFNBZCFDBMDVMBUFEVTJOHUIFGPMMPXJOHGPSNVMB&YIBVTU UFNQFSBUVSFBOEJOUBLFBJSnPXSBUFNVTUCFEFUFSNJOFEUPDBMDVMBUFUIF FYIBVTUnPXSBUF&YIBVTUUFNQFSBUVSFBOENBOVGBDUVSFSTNBYJNVN backpressure may be approximated using the chart on the right.

The calculations on the right are provided as a reference and may be helpful as you validate and select Donaldson mufflers and components. For the most accurate engine airflow and exhaust flow rates, Donaldson recommends using the information supplied by your engine manufacturer.

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Medium- and Heavy-Duty Exhaust Products t 7

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Engine Aftermarket Exhaust Warranty

The information below is the exhaust portion of our Engine Aftermarket Filtration & Exhaust Warranty Document: F110064 (February 2006)

Donaldson warrants its Aftermarket products against failure due to defects in materials and XPSLNBOTIJQGPSUIFQFSJPETQFDJmFEVOEFS5FSNTBOE$POEJUJPOTGPSUIFQBSUJDVMBSQSPEVDU %POBMETPOTPCMJHBUJPOVOEFSUIJTXBSSBOUZDPWFSTSFQMBDJOHUIFGBJMFEQSPEVDU JODMVEJOH USBOTQPSUBUJPODIBSHFT POMZ*GUIF%POBMETPOQSPEVDUGBJMVSFJTUIFTPMFBOEEJSFDUDBVTF PGEBNBHFUPUIFFRVJQNFOUPOXIJDIUIFQSPEVDUXBTQSPQFSMZJOTUBMMFE %POBMETPOXJMM reimburse reasonable costs to restore the equipment to the condition it was in immediately CFGPSFUIFGBJMVSF5IJTXBSSBOUZEPFTOPUDPWFSGBJMVSFEVFUPNJTBQQMJDBUJPO NJTVTF BCVTF OFHMFDU SVTUUISPVHIBOEDPSSPTJPO NVGnFST JNQSPQFSTFSWJDFQSBDUJDFTPSOPO%POBMETPO approved modifications. Engine and equipment manufacturers warranties remain in effect when Donaldson products are used. Donaldson must be notified in writing of any claims covered by this warranty within one year PGUIFEBUFPGGBJMVSF%POBMETPO BUJUTEJTDSFUJPO XJMMFJUIFSQIZTJDBMMZWJTJUUIFTJUFXIFSFUIF BMMFHFEGBJMVSFIBTCFFOGPVOEPS SFRVFTUUIBUBMMQBSUT %POBMETPOBOEPUIFSSFMFWBOUQBSUT CF TIJQQFEQSFQBJEUPJUT(FOFSBM0GmDF JODBSFPGUIF1SPEVDU-BCPSBTPUIFSXJTFTQFDJmFE Terms & Conditions Warranty coverage begins on the date and mileage the product is purchased by the user and FYQJSFTXIFOUIFTQFDJmFEOVNCFSPGZFBSTPSNJMFTIBTQBTTFE XIJDIFWFSPDDVSTmSTU The length of warranty for replacement products provided under warranty coverage is the balance of the warranty period remaining on the product being replaced. Warranty Length by Product Exhaust Products Warranty from Date of Delivery to User %JFTFM.VGnFST 7FSUJDBM*OTUBMMBUJPO :FBSTPS NJMFT LN )PSJ[POUBM*OTUBMMBUJPO :FBSTPS NJMFT LN

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EXHAUST ACCESSORIES

Section Index Exhaust Accessories

Donaldson offers and extensive line of accessories available in a variety of materials for both vertical and horizontal exhaust systems.

Exhaust System Components ...................10 Common System Configurations...............11 Exhaust Joint/Connections ........................12 Exhaust Clamps....................................13-17 SealClamp™ Band Clamps ...........................13 Offset MaxGrip™ Bent Bolt..........................14 MaxGrip™ Bent Bolt.....................................14 SealClamp Band Clamp ................................15 Torca® Clamps ............................................16 U-Bolt Clamps...............................................16 Muffler Body Band Clamps...........................17 Heavy-Duty Muffler Body Band Clamps .......17 Heat Sleeves & Heat Wraps ......................18 Flex Tubing & Cut to Length Flex ..........18-19 Bellows Section .........................................19 V-Band Clamps for Large Mufflers............ 20 V-Band Clamps for Flanged Connections..20 V-Band Clamps ......................................... 20 Flared Connectors & Adapters..................21 Marmon Flange & Flares .......................... 21 Reducers/Expanders............................ 22-23 Connectors ............................................... 22 Tilt Cab Ball & Cone Connectors ..............23 Y or Wye Adapter Pipe.............................. 23 Splitter Tee Adapter................................... 23 Stack Caps ................................................ 24 Universal Swivel Hanger........................... 24 Universal Mounting Bracket .....................24 Pipe Hangers ............................................ 24 Universal Pipe Guards & Clamps.............. 24 Elbows & Bent Tubes........................... 25-28 Straight Tubing & Stack Pipes .............. 29-31 Tailpipes .................................................... 31 Spark Arrestors ......................................... 32 Muffler Guards & Accessories.................. 33 Muffler Hangers........................................ 33 Heavy-Duty Muffler Mounting Straps....... 33 Heavy-Duty Hangers for Round Mufflers........................................34 for School Buses...........................................35 for Oval Mufflers ...........................................35 Universal Applications...................................35 Grab Handles, Manifold Tube/Flange & Threaded Adapters ................................... 36 Exhaust Ejectors & Check Valves .........37-38 Intake Accessories Rubber Elbows .................................... 39-41 Charge Air Connectors .............................42 Worm-Drive Hose Clamps ........................ 43 Vacuator ™ Valves for Air Cleaner ............... 44 Intake Indicators & Indicator Fittings ........ 45 Inlet Hoods ............................................... 48 Air Ram™ Truck.............................................46 Metal & Plastic Hoods ..................................47 Moisture Eliminator & Stack Extensions .. 49 Air Cleaner Mounting Bands Metal Bands ............................................. 50 FPG Plastic & Metal..................................51

Heavy-Duty V-bands, Muffler Bands, Straps and Hangers

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Exhaust System Components

Common Components Of Heavy Duty Exhaust Systems

Bent Tubes & Elbows For directional changes of exhaust flow in exhaust systems. Available in common angles (90°, 67° and 45°) for both O.D. and I.D. tube connections.

Hanger Secures the muffler or pipe horizontally or vertically to chassis or side of cab.

Reducers, Connectors & Expanders Shorter length tubes used for connecting two other exhaust pipes of different diameters or the same diameter. Spark Arrestor An exhaust system add-on used to capture sparks emitted from internal combustion engines through the exhaust system. All Donaldson models are U.S. Forest Service approved. Splitter Tee Adapter An adapter pipe with one inlet and two outlet tubes used to convert a single exhaust system to a dual exhaust system. Stack or Tail Pipes Vertically mounted outlet pipe; available in curved outlet or straight squared configuration.

Wye Connector For joining legs of dual manifold outlet to form a single exhaust system. Wye connectors can provide an additional 3 to 7 dbA exhaust noise reduction over that of the primary muffler and may also be used to replace conventional wye pipe.

Resonator Secondary noise reduction component that generally provides 2 to 3 dbA additional noise reduction.

Tubing (Straight or Flexible) Straight or flexible tubing for connection to muffler or resonator. Purchased in standard lengths and cut to size if needed. Muffler The primary component in an exhaust system for engine noise reduction.

Note: Super stacks also available that can offer an additional 2 to 3 dbA noise reduction with no back-pressure penalty .

Exhaust Filter or Emissions Device Traditional exhaust systems with mufflers are transitioning from noise reduction devices to emissions reduction devices to meet federal and state regulations. The primary component in the emissions device converts or captures exhaust emissions to reduce overall engine emissions. An emissions reduction device can be an add-on installed into the existing system or a retrofit muffler replacing the original muffler.

Stack Cap Moisture protector used on vertically mounted mufflers or stack pipes. Clamps Exhaust systems use a variety of exhaust clamps. Selecting the proper clamp for the job is critical to a strong, reliable joint connection. Common types include u-bolt, band Clamps, bent bolt clamps and v-band clamps.

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Common System Configurations

From the manifold to the exhaust stack, you’ll find Donaldson can be the best source for your exhaust system accessories. The system diagrams below represent typical components found on exhaust systems.

Vertical System Components (cab or stanchion mounted)

« Stack Caps

« Stack Pipes Dump Truck, Straight, Curved, Long 90°, Mitered, Super

Pipe Guard »

« Spark Arrestors Exhaust Ejectors & Check Valves

« V-Band Clamp Flared Connector/Adapter « Manifold Tube & Flange Threaded Adapter

« Clamps Band, U-Bolt, MaxGrip

« Mufflers, see Table of Contents

« Splitter Tee

Reducers/Expanders or Connectors

« Guards & Clamps Grab Handles

« Cut to Length Flex

« Clamps Band, Guillotine, MaxGrip « Elbows

« Resonator

« Clamps Band, Guillotine, MaxGrip

« Elbows

« Bent Tubes Tilt Cab Ball & Cone Connector

Horizontal System Components (Chassis mounted)

« Elbows

« Straight Tubing « Cut to Length Flex

Clamps Band, Guillotine, MaxGrip

« Clamps Band, Guillotine, MaxGrip

Pipe Hangers Swivel Hangers

Muffler Hanger

Tailpipes

Manifold Tube & Flange Threaded Adapter

Straight Tubing Cut to Length Flex

Resonator

“Y” Adapter

Mufflers, see Table of Contents Muffler Body Band Clamps

Medium- and Heavy-Duty Exhaust Products t 11

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Exhaust Joint/Connections Guide to Selecting the Best Clamp for the Exhaust Joint Connection

Type of Clamp to Apply (blue text = primary clamp recommendation)

Type of Joint/Connection

MaxGrip™ Bent Bolt

MaxGrip ™ Bent Bolt Stepped SealClamp (Aluminized or Stainless) Offset MaxGrip ™ Bent Bolt SealClamp ™ Flat Band (Aluminized or Stainless) Narrow Band (Aluminized) U-Bolt (any type, any material)

Offset MaxGrip ™ Bent Bolt

MaxGrip ™ Bent Bolt SealClamp™ Flat Band (Aluminized or Stainless) Narrow Band (Aluminized) U-Bolt (any type, any material)

Offset MaxGrip ™ Bent Bolt (chevron design)

Slotted Tube to Shrunk OD

MaxGrip ™ Bent Bolt (2 required per connection) SealClamp ™ Flat Band (Aluminized or Stainless) U-Bolt (any type, any material, 2 required per connection)

Flat Band SealClamp™

Slotted Tube to Slotted Tube (butt with internal connector)

Stepped SealClamp™

Horizontal Standard Tube to Slotted Tube (overlap)

MaxGrip ™ Bent Bolt Offset MaxGrip ™ Bent Bolt

U-Bolt Single, Round Band

SealClamp™ Flat Band (Aluminized or Stainless) Stepped SealClamp ™ (Aluminized or Stainless) U-Bolt (any type, any material)

Vertical Standard Tube to Slotted Tube (overlap)

U-Bolt Double, Flat Band

Stepped SealClamp ™ (Aluminized or Stainless) Offset MaxGrip ™ Bent Bolt (with chevron)

Standard Tube to Flex Tube

V-Band Clamps

Narrow Band Accuseal®

Flared, Lipped or Flange Connection

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Exhaust Joint Connections Clamp Performance Rankings

Based on the type of exhaust joint, your choice of clamp to apply may be limited. But, when you're looking to purchase a clamp based on specific performance features, the information below may be helpful as you try to select the proper clamp for the application.

Clamp Performance Rankings (10 high - 1 low)

Holding Force 10

Tube Deformation 10 V-band Clamp 9

Offset MaxGrip ™ Bent Bolt

V-band Clamp

Stepped SealClamp (aluminized or stainless)

8 7 5 3

MaxGrip™ Bent Bolt

8 8 7 7 2 2 1

Offset MaxGrip Bent Bolt

U-bolt (any style or material) SealClamp ™ (any style or material)

SealClamp Flat Band (aluminized or stainless)

MaxGrip Bent Bolt

Narrow Band (aluminized)

U-bolt (double, flat band, chrome or zinc)

U-Bolt (double, round band, steel)

Ease of Assembly 9 MaxGrip Bent Bolt 9 Narrow Band (aluminized) 8 Offset MaxGrip Bent Bolt 8

U-Bolt (single, round band, chrome or steel)

Price 10

Stepped SealClamp (aluminized or stainless)

U-Bolt (single, round band, steel) U-Bolt (double, round band, steel)

6 5 3

U-bolt (any style or material)

9 8 8 8 7 7 7 6 3 1

V-band Clamp

Narrow Band (aluminized)

SealClamp Flat Band (aluminized or stainless)

SealClamp Flat Band (aluminized) U-bolt (double, flat band, zinc)

MaxGrip Bent Bolt

Sealing Properties 10

Offset MaxGrip Bent Bolt

Stepped SealClamp (aluminized or stainless)

SealClamp (other than aluminized) U-Bolt (single, round band, chrome) U-bolt (double, flat band, chrome)

9 8 6 6 5 3

V-band Clamp

SealClamp Flat Band (aluminized or stainless)

MaxGrip Bent Bolt

V-band Clamp

Offset MaxGrip Bent Bolt Narrow Band (aluminized) U-bolt (any style or material)

What Features Are Most Important toYou?

Appearance 10

Stepped SealClamp (stainless)

V-band Clamp

9 7 7 7 6 5 5 4 4 2 1

Stepped SealClamp (aluminized)

________ Holding Force ________ Ease of Assembly ________ Sealing Properties ________ Tube Deformation ________ Appearance ________ Price

Offset MaxGrip Bent Bolt Narrow Band (aluminized)

SealClamp Flat Band (stainless) SealClamp Flat Band (aluminized)

MaxGrip Bent Bolt

U-bolt (double, flat band, chrome) U-bolt (double, flat band, zinc) U-Bolt (single, round band, chrome) U-Bolt (double, round band, steel) U-Bolt (single, round band, steel)

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Exhaust Clamps

Offset MaxGrip™ Bent Bolt Clamp

Donaldson introduces a new series of bent bolt clamps for use on exhaust systems. The clamps are manufactured in heavy duty aluminized steel to minimize corrosion. t $MBNQTBSFSFVTBCMF t "MVNJOJ[FECBOE TUBJOMFTTTUFFM welds, deburred strap edges and finished with a heat resistance silver paint t 4FMGQPTJUJPOJOHGPSFBTZJOTUBMMBUJPO t 1SPUFDUFECZQBUFOUT CPUIJTTVFE and pending

Offset MaxGrip Bent Bolt For Muffler to Stack Connections Nominal I.D.

Functional I.D. Range

Part

inches

Number M002164 M001865

4.00 102 5.00 127

4.04-4.21 5.04-5.21

103-107 128-132

Offset MaxGrip Bent Bolt For Tube to Flex Connections Nominal I.D.

Functional I.D. Range

Part

inches

Number M002134 M002135

4.00 102 5.00 127

4.04-4.21 5.04-5.21

103-107 128-132

MaxGrip™ Bent Bolt Clamp

MaxGrip Bent Bolt Clamp Nominal I.D.

t .PSFIPMEJOHQPXFSUIBOBOZ other clamp tested t %POBMETPOQBUFOUFEUFDIOPMPHZ t $MBNQTBSFSFVTBCMF t "MVNJOJ[FECBOE TUBJOMFTTTUFFM welds, and deburred strap edges finished with heat resistant black paint t 6TFUIFTFDMBNQTPOTMPUUFE lapped tube connections and manifold connections t *EFBMGPSVTFPO%POBMETPO “captured” slots for maximum sealing t $PBUFECPMUTBOEUISFBET t )BSEFOFEnBOHFOVUT

Functional I.D. Range

Part

inches

Number M001866 M001867 M002016 M001756 M002050 M001702 M001502 M001593 M001432 M001503 M001566 M002068 M001703 M001668 M001504 M002057 M002070 M001505 M001799 M001506

1.75 44 2.00 51 2.32 59 2.50 65 2.68 68 3.00 76 3.50 89 3.75 95 3.88 99 4.00 102 4.25 108 4.33 110 4.50 114 5.00 127 5.25 133 5.25 133 5.47 139 6.00 152 6.25 159 6.75 171

1.79-1.96 2.04-2.21 2.36-2.56 2.54-2.71 2.71-3.00 3.04-3.21 3.54-3.71 3.73-3.90 3.89-4.06 4.04-4.21 4.21-4.38 4.37-4.53 4.54-4.71 5.04-5.21 5.21-5.38 5.28-5.47 5.51-5.71 6.04-6.21 6.21-6.38 6.83-7.00

45-50 52-56 60-65 65-69 69-76 77-82 90-94 95-99

99-103 103-107 107-111 111-115 115-120 128-132 132-137 134-139 140-145 153-158 158-162 173-178

7.50 198

7.83-8.07

199-205

M002063

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Exhaust Clamps

SealClamp™ –The Original Band Clamp

t 'PSPWFSMBQQJOH*%UP0% slotted joints and flex tube t 'MBUCBOETUZMFNBZCFVTFE for butt-style joints in light duty applications t /VUTBOECPMUTmUCPUI and 14mm wrenches t 3FEVDFTOPJTFBOEFYIBVTU leaks t *OTUBMMTFBTJMZoOP disconnecting or welding necessary t "WBJMBCMFJOBMVNJOJ[FEBOE stainless steel t 4UBJOMFTTNPEFMTIBWF Preformed & Flat Styles Used to seal muffler inlets, outlets, elbow joints, flex pipes, and other system connections. Also minimizes noise and exhaust gas leaks. SealClamps are easy to install! There’s no need to weld or disconnect your exhaust system. When installed, the wide band conforms to the shape of straight or flex pipe, and seals without distorting the pipe.

Stepped Preformed SealClamp t 'VMMDMBNQJOHBSFB t /PnFYQJQFQJODIJOH t "WBJMBCMFJOTUBJOMFTTBOE aluminized

O.D. Pipe in

Stainless Aluminized

2.50 3.00 3.50 4.00 5.00 6.00

64 76 89

X007829 X007830 X007831 X007784 X007785

X007833 X007834 X007824 X007805

102 127

Stepped Preformed SealClamp

152 X009076 U.S. Patent Nos. 6,116,659; 6,634,607 B2; 6,796,004 B2

Stepped Preformed SealClamp is Individually packaged with installation instructions

Flat Band SealClamp O.D. Pipe in mm

Stainless Aluminized

2.00 2.25 2.50 2.75 3.00 3.50 4.00 4.50 5.00 6.00

51 57 64 70 76 89

X004536 X004537 X004476 X004538 X004478 X004480 X004482 X004962 X004484 X004539

Flat Band SealClamp

improved corrosion resistance and high temperature strength compared to aluminized

X006204 X006203

May be used for butt-style joints in light duty applications

102 114 127 152

X006202

Donaldson Flat Band SealClamps are Individually packaged. Loose parts inside the shrink wrapped package.

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Exhaust Clamps

Torctite ®

Easyseal ®

O.D. Pipe

Polished

mm Aluminized Stainless Stainless

2.00 2.25 2.50 2.75 3.00 3.50 4.00 4.50 5.00 6.00

51 57 64 70 76 89

J190056 J190057 J190058 J190059 J190060 J190061 J009623 3 J190062 J009624 4 J190063

May be used for lap and butt-style joints

O.D. Pipe

304 Bright Stainless

J009604 J009605 J009606 1 J190054 J190054 2 J190055

2.00 2.25 2.50 2.75 3.00 3.50 4.00 4.50 5.00 6.00

51 57 64 70 76 89

J000210 J000212 J000211 J000213 J000214 J000215 J000216 J000219 J000217

102 114 127 152

P222740

P222741 P222742

Torctite ® Lap Joint

1 - Consider X007824 as an alternative 2 - Consider X007805 as an alternative 3 - Consider X007784 as an alternative 4 - Consider X007785 as an alternative

102 114 127 152

Accuseal ®

O.D. Pipe in

J000218 Easyseal ® is a registered trademark of Torca Co.

Aluminized

2.00 2.25 2.50 2.75 3.00 3.50 4.00 4.50 5.00 6.00

51 57 64 70 76 89

J000204 J000205 J000206 J000207 J000200 J000201 J000202 J000208 J000203 J000209

102 114 127 152

Accuseal ® is a registered trademark of Torca Co.

Standard U-Bolt Clamps (All models 3/8-16" UNC-2A)

t %PVCMF flat band

t %PVCMF round band

t 4JOHMF

round band t $PMESPMMFE

steel or Chrome

O.D. Pipe

Zinc

Chrome P206608 P206609 P206610 P206611 P207598

Steel

Chrome

3.00 3.50 4.00 5.00 6.00

76 89

P206600 P206601 P206602 P206603 P207596

2.00 2.25 2.50 2.75 3.00 3.50 4.00 4.50 5.00 6.00

51 57 64 70 76 89

J000220 J000222 J000221 J000224 J000227 J000228 J000230 J000231 J000232 J000233

2.00 2.25 2.50 2.75 3.00 3.25 3.50 4.00 5.00 6.00

51 57 64 70 76 83 89

P206403 P206404 P206405 P206406 P206407 P206408 P206409 P206410 P206411 P207667

102 127 152

102 114 127 152

102 127 152

J009486 J009487

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Muffler Body Band Clamps

Muffler Body Band Clamps forTraditional Mufflers

t)JHIUFNQFSBUVSFCMBDLmOJTI NBUDIFTmOJTIPOOFXPGGSPBENVGnFST t#BOEXJEUI NN

Muffler Body Band Clamps ---- A ---- ---- B ----

---- C ----

Part

Number M002117 M002118 M002119 M002120 M002121 M002122 M002123

5/16-18 UNC

6.00 152 6.62 168 8.50 216 9.00 229 10.08 256 11.06 281 11.84 301

3.75 95 4.00 102 5.00 127 5.50 140 6.00 152 6.50 165 7.00 178

Holes fits 3/8" or 10mm bolt

Heavy-Duty Muffler Body Band Clamps

W-Foot Body Bands t6TFGPSWFSUJDBMPSIPSJ[POUBMNPVOUJOH t#PMUTOPUJODMVEFE

Clamp Notes: t 1JODICPMUTBSFOPUJODMVEFE t.PTUVTFw NN MPOHHSBEFPSHSBEFCPMUT t#BOEXJEUIw NN VOMFTTOPUFE t 3FVTFFYJTUJOHGSBNFNPVOUJOHCPMUT t .BUFSJBMTBSFFJUIFS[JODQMBUFEPSBMVNJOJ[FENJMETUFFM

for Heat Shield Applications ---- A ---- ---- B ----

---- C ----

Part

Number P227803 P229513 P230283

10.00 254 11.00 269 13.00 330

6.28 160 6.50 165 7.75 197

3.5 6.5 6.5

165 165

No Heat Shield Applications ---- A ---- ---- B ----

---- C ----

Part

Number P230282 P230281 P230045

10.00 254 11.00 269 13.00 330

6.28 160 6.50 165 7.75 197

3.5 6.5 6.5

165 165

P227803

P230281 No heat shield stand off

Muffler Body Bands for Schools Buses

P227804

---- A ----

---- B ----

---- C ----.

Part

Number

10.00 256 11.00 279

1.75 1.75

44 44

.40 .40

10 10

P228241 (1) P227804 (2)

1. Bluebird conventional bus with Cat Engine Works 2. Bluebird rear engine bus

Band width 1.5” (38mm)

Medium- and Heavy-Duty Exhaust Products t 17

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Heat Sleeves & Heat Wrap Heat sleeves or heat wrap could reduce the outside temperature of a bare pipe by up to 300°F (149) to 400°F.(204)

Heat Sleeves

Heat Wrap

Sleeve & Wrap Clamps

4MJQTPOUP NN UP NN EJBQJQF NN XJEFSPMM FBTZUPJOTUBMMPO any pipe

Wrap clamps make installation easy! No tools needed.

Length

Part Number

Length

Part Number

Length Part Number (51mm) X50' (15,24m) Roll P235767

(305mm) P235764 (457mm) P235765 (610mm) P235766

1$PG (457mm) Long Clamp 1 1$PG (457mm) Long Clamp

P235768 P235769

Flex Tubing & Cut to Length Flex

Flex Tubing

t'MFYUVCJOH BOEDVUMFOHUIT TIPVMECFJOTUBMMFE in a half extended state. Donaldson flex tubing ships in the half extended state. t .BUFSJBMUIJDLOFTTGPSTUBJOMFTTBOEHBMWBOJ[FEJT NN t 4J[FECZnFY*% t .BUFSJBMUIJDLOFTT

Flex Tubing

--- I.D. ---

10 ft. (3 m) Lengths Stainless Galvanized

25 ft (7.6 m) Lengths 1 Stainless Galvanized

2.00 2.50 3.00 3.50 4.00 5.00 6.00

51 64 76 89

P226151 P226152 P226144 P226145 P226146 P226147 P226153 1

P226148 P226149 P226140 P226141 P226142 P226143 P226150 1

P226132 P226133 P226156 2 P226158 2

P226129 P226154 P226155 2 P226157 2

102 127 152

25 ft. / 7.6m Flex Tubing

10 ft. / 3m Flex Tubing

1 - Size exceeds shipping limits by North American small package carriers. This item must ship by truck. 2 - Shipped on pallet, product is not boxed.

Cutting & Installation Instructions for Flex Tubing - Please see page 74

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Cut-to-Length Flex

Standard Cut to Length Flex

t %FCVSSFEFOET t 4J[FECZnFY*% t 4UBJOMFTTBOEHBMWBOJ[FENBUFSJBM

Standard Cut to Length Flex --- I.D. --- Overall Length in mm in mm

Stainless J240003 P206552 J240004 J240005 P206553 J024850 J240006 P206554 J024836 J034673 J240007 P206555 J024838 J034674 P206556 P206559

Galvanized

UIJDLOFTT NN t .FBTVSFEGVMMZFYUFOEFE

3.00 76

12.00 18.00 24.00 12.00 18.00 24.00 12.00 18.00 24.00 36.00 12.00 18.00 24.00 36.00 18.00 30.00

305 457 610 305 457 610 305 457 610 914 305 457 610 914 457 762

3.50 89

4.00 102

P224479 J024754 J024835 J034743 P224481 J024755 J024837 J034744

5.00 127

Close-up of deburred edge

6.00 152

Flex Cut Lengths with Finished Ends

Cut-to-Length Flex - Finished Ends --- I.D. --- Overall Length in mm in mm Galvanized 3.00 76 18.00 457 P206544 4.00 102 18.00 457 P206546 5.00 127 18.00 457 P206547

t'MFYUVCJOH BOEDVUMFOHUIT TIPVMECFJOTUBMMFEJOBIBMGFYUFOEFE state. Donaldson flex tubing ships in the half extended state. t 0OFFOE0% POFFOE*%TMPUUFE t 4J[FECZnFY*% t 0WFSBMMMFOHUIJODMVEFTmOJTIFEFOET t 8FMEFEUVCFFOET

Long-Life Cut to Length Flex

t *NQSPWFEnFYJCJMJUZ t $POTJTUFOUQSPEVDURVBMJUZoPQUJNJ[FENBUFSJBM choice/consistency t )FBWJFSHBVHFTUBJOMFTTNBUFSJBM PWFSTUBOEBSEnFY NN HBVHF t 6QUPUJNFTMPOHFSMJGFUIBODPOWFOUJPOBMnFY t -FTTMFBLBHFBOEMPXFSFNJTTJPOTEVSJOHUSVDL start up t 4JNQMJmFEJOTUBMMBUJPOoJOTUBMMBUJPOTUSJQBOEnPX direction t &OETTRVBSFDVUBOEEFCVSSFE t *OTUBMMBUJPOMFOHUIJOEJDBUPS t NPOUI NJMF LNXBSSBOUZ PO highway vehicles only)

Long-Life Flex --- I.D. ---

Mid Length 1

mm 305 381 457 533 381 457 533

Stainless P224412 P224415 P224418 P224421 P224515 P224518 P224521

4.00 102

12.00 15.00 18.00 21.00 15.00 18.00 21.00

5.00 127

1 - Length measured in half compressed state

Recommended clamps: Preformed SealClamp or Offset MaxGrip Bent Bolt

Donaldson patented technology

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Sliding clamp

Sliding Clamps

Sliding clamps joints are typically used for male to female connection with flared tube where leak rate is critical (ex: EAT systems). This connection allows longitudinal and radial compensation.

A sliding clamp is composed by 3 parts: A V-Clamp composed by a band, a segment, a trunnion, a screw and a nut A gasket A flare

Trunnion

V Clamp

Screw+nut

Flare

Gasket

Segment

Band

Sliding clamp is in stainless steel 441. Gasket is a wire mesh with graphite. Material

Recommended Torque Specifications

Range of sliding clamps Sliding clamp Dia Kit Part number in mm 2.50 63.5 X770810 3.00 76.2 X770783 3.50 88.9 X770780 4.00 101.6 X770746 4.50 114.3 X770801 5.00 127 X770748 Range of Connection Sliding V-Clamp

Diameter

Recommended torque

Maximum torque

Diameter < 101.6 mm Diameter ≥ 101.6 mm

14 +/-1 Nm 20 +/-1 Nm

16 25

* Total Tubes length

Male Tubes Ø ID in mm

Female Tubes Ø ID in mm

Tubes Length * in mm

Part number Tubes Kit

2.52 3.02 3.52 4.04 4.54 5.04

5.91 5.91 6.50 6.50 6.50 6.50

150 150 165 165 165 165

X770862 X770863 X770864 X770865 X770866 X770867

76.7 89.4

102.6 115.3

128

The fitting value of the smallest tube in the other tube is 35 +/- 15mm. The minimum insertion length has to be 20mm. Tubes are in stainless steel 441 and have to be welded. Mounting specifications

Male tube

Female tube

Male tube

Female tube

Siding clamp can compensate few degrees of misalignment (depending on insertion length). Ø OD =Øx Ø ID =Øx+0.5mm

One of the advantages of the sliding clamp is that it provides a low leak rate. Every clamp assembly meets a maximum leak rate value of 0.5 L/min @ 0.3 bar once they are assembled with the recommended torque. Leak tests

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Clamps for Flanged Connections

V-Band Clamps

V-Band Clamps for Large Diameter Mufflers

V-Insert Section

t5IF7CBOEDMBNQJTBDPNNPO clamp for Donaldson retrofit mufflers t 5IFVOJRVFEFTJHOSFEVDFT service time creates a reliable, leak-free seal between components t1JMPUFEWJOTFSUTFDUJPO facilitates reassembly and alignment for clamping

Band

- Body Dia. -

Part

mm 254 279 330

Number P227750 P212925 P229851

10.0 11.0 13.0

V-Band Clamps for Pipes and Turbo Housing Flanges

Nominal Diameter

V-Insert Sections

Part

--- A ---

--- B ---

--- C ---

Cat

Number P206607 P222018

3406, 3406B, 3176

5.88 149 4.75 121

0.40 10 0.40 10

0.28 7 0.28 7

0.88 22 0.88 22

3176T

Nominal Diameter

V-Insert Sections

Part

-- A --

-- B --

-- C --

Cummins

Number J009618 P222017 P222018 J009612

B Series, #3903652

3.21

0.26 0.26

7 7

0.14 4 0.14 4 0.28 7 0.28 7

0.75 19 0.75 19 0.88 22 0.88 22

C Series L10, M11

4.13 105 4.75 121

0.40 10 0.40 10

t 6TFEUPDPOOFDUWFIJDMF exhaust pipe flange to turbo or engine manifold t .BZBMTPIPMEUIFUVSCP housing flanges t #VJMUUPXJUITUBOEIJHI temperatures produced by heavy-duty engines/turbos t .BOVGBDUVSFEUPUIFIJHIFTU tolerances and meet or exceed OEM specifications for material and quality standards

V555, V902, V903

3.88

Nominal Diameter

V-Insert Sections

Part

-- A --

-- B --

-- C --

Detroit Diesel

Number

6-71T, 12V71, 8.2N, 8.2T P206606 6V53, 6V71, 6V92, 8V92 P206604

4.81 122

0.21 0.21 0.24 0.21 0.21

5 5 6 5 7

0.28 7 0.28 7 0.28 7 0.28 7 0.14 4

0.88 22 0.88 22 0.88 22 0.88 22 0.75 19

3.82

8.2 N, #2069773

J009611 P213191

4.06 103 5.81 148 5.25 133

8V71T

8V71T, 16V-71, 16V92T, P210110 6V92, 8V92 8V92, 8V71, 4-53, 6-71 P206605

4.5

114

0.21

0.28 7 0.28 7

0.88 22 0.88 22

Series 60

P206607

5.88 149

0.40 10

Cross Section

Nominal Diameter

V-Insert Sections

Part

-- A --

-- B --

-- C --

Number J009613

DT466

4.33 110

0.21

0.28 7

0.88 22

Nominal Diameter

V-Insert Sections

Part

-- A --

-- B --

-- C --

Mack

Number J009614

48RU2341, 4ME21409

4.61 117

0.16

0.28 7

0.75 19

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