LNF/LXF Muffler - IOM P484796 (rev 4) - Donaldson Company

Donaldson Retrofit Emissions System Introduction LNF and LXF Muffler Pre-Installation The Donaldson LNF and LXF Mufflers are passive, catalyzed Diesel Particulate Filters (DPFs) designed to reduce Particulate Matter (PM) emissions from in-use diesel engines. These retrofit emissions solutions reduce diesel particulate matter emissions by over 85% and are effective at reducing carbon monoxide and hydrocarbon emissions. Application Pre-Assessment A copy of the Donaldson Application Pre-Assessment can be found at www.Donaldson.com or by contacting Donaldson Engineering. retrofit emissions LNF and LXF Mufflers are reliable and provide substantial benefits in air quality, but require routine DPF cleaning. The LNF and LXF Mufflers consist of a pre-filter and DPF section along with inlet and outlet sections. Removable V-band clamps provide easy access to the DPF for annual ash cleaning. Installers must follow Donaldson installation guidelines to ensure full warranty coverage. For optimum performance, follow all the installation, operation and maintenance recommendations covered in this manual. LNF or LXF Muffler Kit Contents (including Duals) Qty. Description 1 LNF or LXF Muffler Assembly 1 Emissions Device Monitor (EDM) with installation and operation manual. 1 Documentation package that includes this owner’s manual, LNF and LXF Muffler Warranty, a warranty registration worksheet and a Diesel Emissions Control Strategy (DECS) engine tag (ARB requirement). Pre-Installation Requirements Donaldson’s pre-installation requirements are provided below. In order to maximize the diesel emissions control system’s performance and life, the installation must meet these requirements. Failure to follow these instructions may void the warranty and could lead to device failure. Failure to maintain the pre-assessment conditions throughout the life of the retrofit may void the warranty and lead to device failure. 4 Donaldson LNF/LXF Muffler Owner's Manual - P484796 Rev 4 Lube Oil Tests (Lube, Fuel & Opacit y) Filter-based emissions devices over time. require Other problem the s can be caused use of low ash oil (CJ-4). application pre-assessment worksheet Low ash oil by out of spec Test Fuel slows oil. Donalds on recommends the buildup of ash in Filter-based the filter and oil analysis on-road emissions devices reduces the via a third-pa the buildup require ULSD fleet. rty oil testing fuel with less engine if one or older; has accumu lated 200,000 OR, miles End User Vehicle Information Fleet Name: Fleet Vehicle #: VIN #: Vehicle Make: Vehicle Model: Engine Make: Engine Model: Engine Family #: Signature: Inspector’s Name: Inspection Date: or more of the firm. of backpressure followin g conditions (320,000 km An opacity measurem apply: ) or more; OR ent is only an 16,000 operatin particulate approximate matter g hours. indicator issues not detectedemission level above original certificat of engine particulate matter emission levels and cause by the opacity test. ion levels and/or output. It is premature plugging. A single opacity possible that test is a “snapshostandards. In these cases an engine can Vehicle Year: a passive particula t” in time and Opacity Test pass the opacity engine deteriora Method: A te filter may test limit experience snap accelera tion or engine using a “declare premature plugging but still have a component tion opacity Engine Year: d” opacity meter. failure over due to engine time may also A list of “declare test must be conduct Alternative ed following raise emission d” opacity Option: the will accept Dealer Name: meters can If the vehicle SAE J1667 be found on guidelines by has been tested the test result the Californ a certified dealer by a certified printout as ia Air Resourc (California) dealer proof e Board website or a dealer PASS (ü) of opacity FAIL (ü) ent. or a dealer using a “declare assessm . d” opacity meter within the previous OR 30 days, Donalds on Opacity Engine Model Year If any shaded boxes are checked, the vehicle/engine fails pre-assessment may retrofit.Specification thanNOT 1991-1993and Less or equalbe to 1994-2006 2. Are you using CJ-4 oil? If yes, see Section C. 3. Are fuel additives being used? Opacity Readin to Specification g Compared (ü one box) 30% Greater Yes No (ü) than (ü) 30% Less than or equal to 20% Greater than 20% Section A: End User Maintenance Practices 1. Are you using ULSD Fuel? If yes, see Section C. Testing Questio ns 4. Is the engine consuming oil at a rate higher than 1 quart/500 miles? Review maintenance records (if available). (13 CCR An opacity test has been 2706.t.4.A) conducted pre-asse ssment form. and the printout is attached 5. Has the fuel pump or governor setting been changed? to my Is the engine ECU downloa 6. Will the engine be serviced and maintained according to the engine manufacturer recommendations after the emissionsd attached to my pre-assessment The 3rd party device is installed? oil-testing shows form? 7. Does the engine ECU download show any active fault codes? Attach ECU download. 8. a. Has the air filter been serviced/replaced in the last 3 months? Date: at Yes (ü) oil meets CJ-4 Does the fuel oil spec? from the supplier meet ASTM For Spiracle D975 spec Applications: for ULSD fuel? What is the maximum measure to be achieved by accelerati d blow by flow Hrs/Miles ng the vehicle in CFM from standing No (ü) * Full load reading If any shade d boxes are Section B: Visual Inspection CAUTION! Follow Donaldson Installation Guidelines Additional Proper application is critical to ensuring that FILTER-BASED emissions control devices perform as designed and meet the requirements of regulatory authorities.than 15 ppm sulfur. Collect Opacit y Testing and inspect (per SAEemissions Donaldson Certified Retrofit Emissions Dealers are responsible for performing application pre-assessments prior to installing retrofit devices on all fuel from the J1667 guidel An opacity vehicle fuel test and a printout tank and any vehicles. Dealers are also responsible for registering the emissions control devices with Donaldson and reporting the results of all data logging and ines) engine of test bulk tank if - the engine results are feeding model year required for pre-assessments. is 1996 - the engine the b. When was the air filter serviced/replaced? The LNF and LXF Muffler Kit includes an Emissions Device Monitor (EDM) that detects exhaust restriction created during vehicle operation. The monitor provides visual alerts to the vehicle operator to indicate when DPF cleaning is required or if the DPF experiences a high heat condition that could damage the DPF. Filter-based emissions devices Collect require and (delet ULSD fuel e test) inspec any bulk with less t fuel from tank if feedin than 15 vehicle ppm sulfur g the fleet fuel tank . and Section C: Test Engine (ü) checkYes ed the 1. With the engine at normal operating temperatures, snap to high idle. Do you see Sectio excessive of white or blue n D:amounts Duty Cycle Data Logging Evaluation smoke exiting the tailpipe? can proceed – Data No (ü) vehicle/engine Logging when the pre-asse ssment inspecto Results r has signed and worksheet. 2. Is there noticeable oil or fuel residue on the exhaust tailpipe? (13 CCR 2706.t.4.D) 3. Does it look like the governor and any seals/cover protecting it have been tampered with? 1. start to 35 mph, The histogram 2. Will this histogram 5. For engines equipped with EGR, does it look like the EGR valve and any seals/cover protecting it have been tampered result be used for other vehicles 3. The Donaldso with? in the fleet? n 6. Are there any exhaust leaks in the entire exhaust system (manifold to tailpipe)? data logger was used to collect duty Date: Measured Flow: fails pre-assess ment and may checked PASS report from data logging 4. Does it look like the fuel injection pump and seals/covers protecting it have been tampered with? (mechanical injection allowed applicati on of the following only) control at full load? using full throttle. technology on the front ( ü all that page of this Yes (ü) cycle data. NOT be retrofi t. application pre-assessment DOC apply) LNF/LXF SEF No (ü) 7. Inspect the inside edges of the outlet or stack pipe with a white rag or glove. Is there excessive PM or fuel, oil North or America coolant residue present? Sales: 866-675-28 8. Is there any oil leaking from the exhaust manifold seals? (13 CCR 2706.t.4.C) 9. Are there any Engine Warning Lights activated? 10. Are there any leaks around the turbocharger? 11. Are there any leaks around the oil coolers? (13 CCR 2706.t.4.C) Email: emissionssa47 les@donald son.com Technical Support: Email: emissions@ 866-617-8733 donaldson.c om Doc. No. F114050 2012 Donaldson (6/12) Company, Inc. Inc. reserves All rights reserved. the right to change or discontinue Printed in the notice. U.S.A. Donaldson any model or Company, specificatio n at any time and without Company, Inc., PO Box 1299, Minneapo lis, MN 55440-1299 Donaldson 12. Are there any leaks around the radiator? 13. Crankcase blow-by vent weepy/oily on exit port? Additional Testing & Data Logging (Section C & D) on reverse side. 1. Verify that the application PASSED the Donaldson Application Pre-Assessment conducted by a Certified Emissions Dealer. A basic assessment of the engine must also be performed no more than 15 days prior to installation. The pre-assessment worksheet and opacity test results need to be forwarded to Donaldson upon warranty registration. 2. The application pre-assessment confirms the following: The engine family number (EFN) for the vehicle is included in the California Air Resources Board (ARB) -Approved Engine Family Numbers on the Executive Order. Vehicle and engine have been properly maintained Vehicle passed the pre-assessment visual system inspection Opacity test results collected meet Donaldson requirements (based on SAE J1667 test specification) Vehicle engine duty cycle meets the application temperature criteria. 3. Vehicle must be data-logged prior to application of the Donaldson LNF/LXF Muffler Kit to ensure the engine duty cycle meets the application criteria. Follow Donaldson data logging requirements. Alternate data logging approaches may not provide an accurate picture of operating temperature and may result in unsatisfactory operation. Contact Donaldson Engineering to review compatibility of data logging approaches. 4. Retain the Donaldson data logging response letter and data log to confirm compliance with application criteria. A copy of these documents will be required at the time of warranty registration and should be kept in the vehicle as they may be requested by California ARB or other enforcement staff.

Donaldson Retrofit Emissions System 5. Only apply an LNF/LXF Muffler when approved by Donaldson or a Donaldson certified dealer in writing via a formal data logging response letter. Applying an LNF/ LXF Muffler to a vehicle that does not meet exhaust gas temperature (EGT) criteria in the California ARB Executive Order would be an illegal device. 6. Be sure to plug the welded fitting where the thermocouple was installed after data logging to prevent exhaust leakage. Applying an LNF or LXF Muffler These LNF or LXF Mufflers have been verified by California ARB for specific engine families. Prior to installing, make sure the engine on the vehicle being retrofitted is listed on the California ARB Executive Order attachment. Application of the LNF or LXF Muffler on an engine model other than those approved is considered an illegal device and may result in denial of warranty coverage or fines. Inspect Mounting Hardware An LNF or LXF Muffler weighs considerably more than a traditional OEM truck muffler (80 lbs. vs. 30 lbs. [35 kg vs. 13.6 kg]). Dual LNF/LXF weigh even more (9.5" model is 144 lbs. [65.3 kg]; 10.5" model is 173.5 lbs. [78.6 kg]). Inspect any mounting system hardware intended for reuse to ensure it is in good condition and can adequately support the added weight. Look for signs of rust, corrosion or fatigue. Do not reuse suspect components. New heavy-duty components should be used. The body mounting clamps are provided with the dual LNF/LXF. NOTE Inspect Mounting Hardware LNF or LXF Mufflers are two to six times heavier than a traditional OEM truck muffler (depending on configuration). The mounting system should be inspected to ensure it is in good condition and can adequately support the added weight. Inspect all hardware intended for reuse for rust, corrosion or fatigue. Replace all questionable components with heavyduty components. Verify that the LNF or LXF Muffler model selected is sized appropriately for your engine and best matches your existing muffler configuration. (See the Donaldson LNF/LXF Muffler Brochure F111248 for available styles and configurations). NOTE on average. Thus, the expected fuel consumption increase will be 0.5%. Given the vast differences in duty cycles for on-road vehicles, this would not be a measurable difference. Backpressure Increase Engine Must Meet OEM Specifications The LNF/LXF System could increase the nominal engine backpressure by 20" H2O (1.46" Hg) compared to stock exhaust system. When the LNF/LXF Muffler is loaded with soot, the engine backpressure can increase to 100" H2O (7.36" Hg) or 127" H2O (9.34" Hg). The engine must be inspected by a qualified technician to verify the engine is operating within the engine OEM’s specifications. If the engine does not meet specifications, necessary repairs must be made prior to LNF or LXF Muffler installation. The technician must document compliance on the Donaldson warranty registration web site. Fuel Requirement Noise Level Control The LNF and LXF Mufflers require the use of ULSD Fuel (15 ppm or less sulfur content) that meets ASTM D975. B20 BioULSD (20% biodiesel/80% ULSD) per ASTM D6751 diesel fuel specifications may also be used. Fuel additives are not permitted and may void your warranty. Expected noise level of the LNF/LXF System will be equal to or less than the stock exhaust system. Engine Lube Oil Requirement Fuel Penalty The effect of an LNF/LXF System on fuel consumption is negligible. SAE Paper 810858 – ‘Fuel Efficient Exhaust Systems’ outlines fuel consumption of a turbocharged diesel engine with respect to backpressure. It states that fuel consumption will increase 0.5% for every 1" Hg backpressure over the manufacturer’s specification. The LNF/LXF System will increase backpressure on the engine compared to a stock muffler. However, the expected increase will be less than 1" Hg The LNF and LXF Mufflers require the use of engine lube oil that meets CJ-4 specifications (low ash). The engine must NOT be consuming oil higher than a rate of 0.5% of oil to fuel ratio or 1 quart/500 miles, whichever is lower. Avoid Vibration The LNF or LXF Muffler should be mounted as close to the engine as possible, but must be isolated from engine vibration. If not isolated properly, vibration may damage the exhaust system or the retrofit muffler. Do not hard-mount the muffler assembly directly to the engine or install where the device can be subject to vehicle or equipment vibration. Donaldson LNF/LXF Muffler Owner's Manual - P484796 Rev 4 5

Donaldson Retrofit Emissions System Minimize Exhaust Tubing Lengths The engine EGT has an affect on emissions performance. To optimize performance, the LNF or LXF Muffler inlet must be installed within 6" (152 mm) from where the temperature probe was installed during preliminary temperature data logging to ensure the EGTs are representative of what the LNF or LXF Muffler will see. It is also a good idea to minimize the distance from the turbo to the emissions device inlet. NOTE Mount the LNF or LXF Muffler within 6" (152mm) from temperature probe To optimize performance, the inlet on the new DPF must be installed within 6" (152 mm) from where the temperature probe was installed during preliminary data logging. Mounting the LNF or LXF Muffler beyond this distance may cause frequent cleaning intervals and may result in unsatisfactory / unreliable performance or plugging. Vertical Tailpipe Support Vertical tailpipes over 4 ft. (1.2 m) require additional support. Tailpipes at this length, over time will start to vibrate and cause unwanted stress on the outlet section. To prevent this failure, support the outlet stack appropriately. Inspect Tubing The following section includes separate procedures for vertical and horizontal installations. Please use the procedure that matches your intended muffler orientation. Review and meet all pre-installation requirements before proceeding with the installation. NOTE Engine Problems Must be Resolved PRIOR to Installing the LNF or LXF Muffler LNF and LXF Mufflers may plug if the engine is not properly maintained. This is especially true when operated under low-load or low ambient temperature conditions, idled for extended periods of time or if the engine is not properly calibrated for the specific fuel-type being used. To prevent the occurrence of plugging, engine problems must be resolved prior to installing the LNF or LXF Muffler. Ensure the engine meets OEM specs. Install Tip Save Install Time if Disposing of the Old Muffler and Components It's not a good idea to reuse old exhaust components on new retrofit emissions installations. So, if your installation plan is to discard the old components, reduce install time by using a Sawzall to cut the muffler and old clamps out of the exhaust system. Sawzall is a registered trademark of the Milwaukee Electric Tool Company To maximize effectiveness, exhaust and flex tubing should be structurally sound and leak-free. Inspect the exhaust tubing for damage or corrosion and replace defective components. Also look for flaking due to corrosion and/or soot build-up. Loose contaminants can be blown onto the DPF face and cause increased backpressure and degraded engine performance. NOTE Installation Rust, Corrosion and Soot on Existing Exhaust Tubing If you see any evidence of rust or corrosion on existing tubing between the turbocharger and LNF or LXF Muffler inlet, replace with new aluminized steel tubing. If reusing existing exhaust tubing, banging and tapping on the tubing may dislodge soot. Be sure to clean out any pipes prior to installing new components. Operate engine at high idle to blow out exhaust pipes prior to the installation of the emissions device. Protect yourself and others from loud noise and flying debris. CAUTION! Do Not Install Mounting Brackets Over Pre-filter or DPF Sections To avoid damage or deformation to the pre-filter and DPF Section of the muffler, apply mounting brackets to inlet and outlet sections only. 6 Donaldson LNF/LXF Muffler Owner's Manual - P484796 Rev 4 Vertical Muffler Installation Remove the Existing Muffler 1. Loosen stack clamp at muffler outlet (top). Remove stack and clamp. 2. Loosen tubing clamp at muffler inlet (bottom). 3. Loosen clamps on flex tubing. Remove clamps, flex and elbow. 4. Remove heat shield mounting brackets. 5. Loosen muffler and remove. Dispose of or recycle old muffler. Clamp S t a n c h i o n Mounting Bracket V-band Clamps (3x) Mounting Bracket Clamp

Donaldson Retrofit Emissions System NOTE Install the LNF or LXF Muffler 1. Inspect the mounting brackets, bands, supports and/or stanchion for any damage, cracks or corrosion. Replace any existing mounting parts that appear rusted, damaged or of questionable strength with heavy-duty parts. Mounting components must be strong enough to support the LNF or LXF Muffler, which weigh roughly 80 lbs. (35 kg). Dual LNF/ LXF’s weigh considerably more (9.5" model is 144 lbs. [65.3 kg]; 10.5" model is 173.5 lbs. [78.6 kg]). Donaldson offers many components designed specifically to handle the added weight of emissions retrofit devices (excluding dual LNF/ LXF). 2. Ensure the LNF or LXF Muffler is installed so that flow arrows match the exhaust flow direction. Place muffler/heat shield mounting brackets around the LNF or LXF Muffler body and finger-tighten. Rotate LNF or LXF Muffler so ARB emissions device tag is visible. Tighten (snug fit) mounting bracket bolts to hold the LNF or LXF Muffler in place. 7. Operate vehicle and check for exhaust leaks. Repair any leaks. 8. Turn off the engine. 9. Permanently attach the DECS engine tag (supplied in documentation package) onto the engine using high-temp RTV or a screw. ARB regulations require the DECS engine tag be installed in a location clearly visible to Enforcement staff. Application of the engine tag is necessary for all retrofit programs. Permanently affix DECS Engine Tag onto Engine 10. Install Emissions Device Monitor (EDM). Installation instructions will be included with the monitor (manual P484891). 3. Position tubing and clamps (i.e., SealClamp ) onto exhaust tube. Do not tighten clamps until all tubing is assembled. Flex is not approved in all locations. Check local ordinances or retrofit program rules. Horizontal Muffler Installation 4. Position inlet elbow and muffler inlet clamp. Locate flex tube so that there are equal lengths of rigid tubing (within the flex) on both ends. Tighten clamps to secure flex tubing and inlet elbow to the emissions device inlet section. NOTE 6. Verify that all bolts and fasteners have been sufficiently tightened. California ARB regulations require a DECS engine tag be permanently installed on the engine in a clear, visible location. Use high-temp RTV or screw. The pre-filter and DPF inside could be damaged if you deform the muffler body by overtightening the clamps. NOTE Water can also damage the DPF retention material inside the device. Vertical tail pipes must be fitted with rain caps or rain resistant stack. NOTE CAUTION! Do Not Overtighten Bands or Clamps on Muffler Body Water from Rain and Truck Washing Can Damage the DPF Remove the Existing Muffler Install Tip Avoid Excessive Force on Inlet and Outlet Piping! Excessive force on the inlet and outlet piping in conjunction with vehicle vibration can result in stress cracking on the pipe or the emissions device inlet. Failures caused by excessive force are a result of improper installation and are not covered by warranty. 5. Position clamp over outlet tube on the LNF or LXF Muffler outlet section. Insert the stack into the muffler outlet and tighten securely. Vertical tailpipes over 4 ft. (1.2 m) require additional support. Install a rain cap or rain resistant stack. Save Install Time Use a ComeAlong Winch to Remove Muffler On horizontal muffler installations, a come-along winch can be used to pull the OEM outlet piping back far enough to remove the existing muffler. This same tool is also helpful when installing the new LNF or LXF Muffler. 1. Loosen clamp at muffler outlet. Remove clamp and tailpipe. 2. Remove clamp at muffler inlet. 3. Loosen muffler mounti

Donaldson LNF/LXF Muffler Owner's Manual - P484796 Rev 4 3 Donaldson Rerofl ssons se LNF or LXF Muffler Kit Illustration Emissions Device Monitor (EDM) . Donaldson Certified Retrofit Emissions Dealers are responsible for performing application pre-assessments prior to installing retrofit emissions devices on all