Quick Start Guide TK3/TK4 Thermal System Assembly and Fan Shroud Assembly This Quick Start Manual is effective for Consumer installations of the part numbers listed in Table 1 and Table 2. OEM installers must contact EMP for production requirements. Rev Rev By Date Description of Change Approved By A SRS 10/18/17 New Release ECN4822 9970031082_Rev. A 10/18/2017 2017 EMP, Inc. 1
Product Overview/Technical Help Engineered Machined Products Inc. 2701 North 30 th Street Escanaba, MI, USA 49829 Phone: +1 (906) 789-7497 www.emp-corp.com Service@emp-corp.com Product Overview The EMP TK3/TK4 Thermal System Assembly is a revolutionary advanced thermal product designed for applications requiring cooling of natural gas engine water jacket circuits, power electronic components or any other general cooling application using water/ethylene glycol or similar coolant. Benefits include lower energy consumption, reduced noise, individual fan diagnostics and improved temperature control. Technical Help Contact EMP Customer Service for technical help at +1 (906) 789-7497 or service@emp-corp.com. Additional information about this product is located under the support tab of the EMP official website: www.empcorp.com. Service parts and the full Service Manual for this product can be obtained at http://www.empcorp.com/support/documents by searching for the system s part number. The information contained in this manual is updated periodically. While great care is taken in compiling the information contained in this manual, Engineered Machined Products, Inc. cannot assume liability for losses of any nature arising from any errors and/or omissions. The information and specifications contained throughout this manual are up to date at the time of publication. Engineered Machined Products, Inc. reserves the right to change the content of this manual at any time without notice. 2017 EMP, Inc. 2
Table of Contents Table of Contents Product Overview... 2 Technical Help... 2 Table of Contents... 3 Introduction... 4 Purpose... 4 Service Technician Responsibilities... 4 Liability Disclaimer... 4 Definition of Terms... 4 Safety... 5 Warnings, Cautions & Notes... 5 Product Safety Warnings... 5 List of System Part Numbers for This Manual... 6 Explanation of Function... 7 FiL-11 Fans and μtmc System Controller... 7 TK3 and TK4 Schematics... 8 Diagnostic LED... 8 Service Tool Interface... 9 Troubleshooting... 10 Service Tool... 10 Power and Ground Stud Assembly Details... 11 Component Greasing... 12 Routine Maintenance... 13 Minimum Coolant Quality Requirements... 13 System Pinouts... 14 System Mounting Hole Locations... 15 Wiring Schematic... 16 2017 EMP, Inc. 3
Introduction Introduction Purpose The purpose of the Quick Start Guide is to present information for installing and using your cooling system. Full service and maintenance instructions for your cooling system are available on the EMP website at http://www.emp-corp.com/support/documents by searching for the system s part number. Service Technician Responsibilities Ensure that all safety messages and information messages are read and understood before installation, maintenance, or any repairs are performed. The person who services the system may be unfamiliar with many of the components on the product. It is important to use caution when service work is performed. Knowledge of the system and operation are important before the removal or disassembly of any component. Liability Disclaimer EMP cannot anticipate every possible circumstance that might involve a potential hazard. The safety messages in this document, in related manuals, and on the product are therefore not all inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by EMP is used, you must satisfy yourself that it is safe for you and for others. You should ensure that the product will not be damaged or be made unsafe by the operation, maintenance, or repair procedures that you choose. Definition of Terms LH = Left Hand RH = Right Hand CAC = Charge Air Cooler JW = Jacket Water LED = Light Emitting Diode EMP-Link = EMP LIN Based Proprietary Serial Data Bus µtmc = Micro Thermal Management Controller FiL-11 = 11 Fan with Integral Controller and EMP- Link Communications 2017 EMP, Inc. 4
Safety Safety Warnings, Cautions & Notes Three types of headings are used in this manual to stress your safety and safe operation of the system. They appear in the text as follows: WARNING: This symbol is used to make you aware of an unsafe condition, hazard, or practice that can result in personal injury or death. CAUTION: This symbol is used to alert you to a condition or practice that can cause damage to the system or the vehicle, or both. NOTE: Is used to provide additional information that requires special attention by the technician. Product Safety Warnings WARNING: EMP cannot anticipate every possible circumstance that might involve a potential hazard. The safety messages in this document, in related manuals, and on the product are therefore not all inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by EMP is used, you must satisfy yourself that it is safe for you and for others. You should ensure that the product will not be damaged or be made unsafe by the operation, maintenance, or repair procedures that you choose. WARNING: Ensure that all safety messages and information messages are read and understood before installation, maintenance, or any repairs are performed. The person servicing may be unfamiliar with many of the systems on the vehicle. It is important to use caution when service work is performed. Knowledge of the vehicle system and operation are important before the removal or disassembly of any component. WARNING: Make sure the equipment cannot move while being serviced. If on vehicle, ensure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before doing any work or diagnostic procedures on the EMP component, system, or vehicle. WARNING: Disconnect the power supply, main negative battery cable, and/or switch off the battery disconnect switch before installation or servicing. When working on or near the electric fans, ensure battery power is off or lock out vehicle ignition, so the system cannot activate unexpectedly. WARNING: Use extreme caution when working on systems under pressure (i.e. coolant, hydraulic fluids, air, fire suppression, etc ) WARNING: Make sure the work area is ventilated and well lit. WARNING: Make sure charged fire extinguishers are in the work area. WARNING: Reinstall all safety guards, shields, and covers after servicing the equipment or vehicle. WARNING: Make sure all tools, parts, and service equipment are removed from the equipment, engine compartment, and/or vehicle after all work is done. WARNING: Ensure that all system power and ground connection points are properly secured. Improper attachments at any point of the equipment or vehicle system power and ground can result in loose connections which can damage electronic components on EMP components and systems and will void EMP warranty. 2017 EMP, Inc. 5
List of System Part Numbers for This Manual List of System Part Numbers Table 1 - TK4 Shroud Only Part Numbers Part Number Serial Number Description 1940031016 All 12V TK4 Fan Shroud Assembly 1940031026 All 24V TK4 Fan Shroud Assembly 1940031050 All 12V TK4 Fan Shroud Assembly 1940031051 All 24V TK4 Fan Shroud Assembly 1940031052 All 12V TK4 Fan Shroud Assembly 1940031053 All 24V TK4 Fan Shroud Assembly 1940031062 All 12V TK4 Fan Shroud Assembly 1940031063 All 24V TK4 Fan Shroud Assembly 1940031064 All 12V TK4 Fan Shroud Assembly 1940031065 All 24V TK4 Fan Shroud Assembly 1940031066 All 12V TK4 Fan Shroud Assembly 1940031067 All 24V TK4 Fan Shroud Assembly Table 2 - TK3 and TK4 w/heat Exchanger Part Numbers Part Number Serial Number Description 2020031007 All 12V TK4 with Heat Exchanger 2020031020 All 12V TK3 with Heat Exchanger 2020031021 All 24V TK4 with Heat Exchanger 2020031022 All 24V TK3 with Heat Exchanger 2020031054 All 12V TK4 with Heat Exchanger 2020031055 All 12V TK3 with Heat Exchanger 2020031056 All 24V TK4 with Heat Exchanger 2020031057 All 24V TK3 with Heat Exchanger 2020031058 All 12V TK4 with Heat Exchanger 2020031059 All 12V TK3 with Heat Exchanger 2020031060 All 24V TK4 with Heat Exchanger 2020031061 All 24V TK3 with Heat Exchanger 2020031068 All 12V TK3 with Heat Exchanger 2020031069 All 24V TK3 with Heat Exchanger 2020031070 All 12V TK4 with Heat Exchanger 2020031071 All 24V TK4 with Heat Exchanger 2020031072 All 12V TK4 with Heat Exchanger 2020031073 All 12V TK3 with Heat Exchanger 2020031074 All 24V TK4 with Heat Exchanger 2020031075 All 24V TK3 with Heat Exchanger 2020031076 All 12V TK4 with Heat Exchanger 2020031077 All 12V TK3 with Heat Exchanger 2020031078 All 24V TK4 with Heat Exchanger 2020031079 All 24V TK3 with Heat Exchanger 2017 EMP, Inc. 6
Explanation of Function Explanation of Function FiL-11 Fans and μtmc System Controller The fans and system controller are powered by the 12V or 24V electrical system. The system will consume a maximum of 100 amps at full cooling potential. The fans and system controller receive power through the red positive and black negative stud located on the system. The wake-up line (ignition enable) is a 9-32V switched power source sent from the chassis or a PLC to initiate operation of fans and system controller. Current consumption is related to fan speed and in some applications the maximum fan speed may be restricted due to lower heat rejection requirements. In these applications maximum current consumption will be much less. Each of the fans and the system controller is protected by a 30A fuse. The TK3/TK4 also contains a 3 pin connector for interfacing with a PC based service tool via EMP-link. Each of the FiL-11 brushless fans within the TK3/TK4 system is powered by an internal controller. The primary function of these controllers is to control fan speed and direction as commanded via EMP-link by the μtmc System Controller. If one or more FiL-11 controllers lose communications on the EMP-link bus when the ignition enable is at rated voltage it will go to a default speed until the communication problem is corrected. Each of the FiL-11 fans are identical and are interchangeable however they each have a unique EMP-link address that is set by resistors within the wiring harness. These EMP-link addresses allow the FiL-11 fans to report status information back to the μtmc System Controller for enhanced diagnostics. 2017 EMP, Inc. 7
Explanation of Function TK3 and TK4 Schematics Optional Push Button 3 Sc e at c 3 Pin EMP-Link Diagnostic Connector 12V or 24V Wakeup Enable Coolant Temp Sensor Air Temp Sensor Diagnostic LED utmc Controller 12V or 24V Wakeup Enable EMP-Link Fan 1 Fan 2 12V or 24V Powe r 30A 30A 30A Fan 3 Fan 4 30A Ground 30A 12V or 24V Gnd Figure 1 TK3/TK4 Fans and Controllers NOTE: The TK3 systems use the same harness as the TK4 systems. The fan 1 connector on the harness for the TK3 systems will get plugged with a cap. Diagnostic LED A diagnostic LED located on the RH side of the system will give indication of a system problem if detected. This diagnostic LED will flash out blink codes to the technician to indicate the source of the fault when the vehicle is running. The format for the blink fault codes is as follows: XX-YY where: XX is the first number of the fault code YY is the second number of the fault code The blink codes are read out in the following manner: 1. Warning lamp on for 4 seconds to mark the start of the fault code list. 2. Off for 2.5 seconds to indicate the start of a fault code. 3. A sequence of.5 second blinks the number of which indicates the first number (XX) of the fault code. 4. Off for 1.25 seconds to indicate the start of the second digit of the fault code. 5. A sequence of.5 second blinks the number of which indicates the second number (YY) of the fault code. 6. If multiple fault codes are active, the next fault code will be communicated beginning with step 2. When all fault codes have been communicated, the fault code list will be repeated beginning with the long on time of step 1. 7. The sequence will be repeated until the fault condition is removed or cleared manually. 8. The blink codes can be found in the Troubleshooting Manual or in the help menu of the Service Tool. 2017 EMP, Inc. 8
Explanation of Function Service Tool Interface Figure 2 TK3/TK4 Service Tool Connector 1. Remove the sealed cap from the 3 pin service tool connector 2. Insert the 3 pin mating connector from the EMP-link DLA harness 3. Apply the enable signal to the system 4. Follow the instructions for service tool installation and operation. This tool can be used for monitoring data, viewing diagnostic information, downloading new calibrations and downloading history data. 5. When finished, unplug the DLA harness and re-install the sealed cap NOTE: EMP Service Tool Harness and data link adapter system is part number 7500038005 CAUTION: The sealed cap must be installed after using the service tool interface to prevent moisture intrusion into the harness. 2017 EMP, Inc. 9
Explanation of Function Troubleshooting Use EMP Service Suite to communicate with the system, troubleshoot, and obtain fault information. Software can be obtained at no charge from the EMP website at http://www.emp-corp.com/support/downloads. Service Tool A PC based tool called the Simple Service Tool (part of the EMP Service Suite) is available from EMP. Simple Service Tool is available in the EMP tools folder after installing the Service Suite (Start All Programs EMP Tools Simple Service Tool). Use of the tool requires an interface cable and a USB-TTL/EMP-Link converter both of which are available in a kit form from EMP part number 7500038005. The Simple Service tool interfaces with the µtmc system controller and displays controller configuration, fault code history, and real time operational data such a current fan speed commanded and read along with hours of operation and fluid temperature. The tool also allows the fans to be turned on manually and enables the download of system history data. The system must be powered up and enabled to connect with the Simple Service Tool. See Figure 3 for the Simple Service Tool Display. Figure 3 2017 EMP, Inc. 10
Explanation of Function Power and Ground Stud Assembly Details CAUTION: Ensure that all system power and ground connection points are torqued to EMP specifications to prevent system damage. Failure to follow specified torque requirements at any point of the vehicle system power and ground can result in loose connections which can damage electronic components on the cooling system and will void EMP warranty. NOTE: Older systems may have an additional nut on the stud assemblies. Reference the decal label on your system for details. Figure 4 Power and Ground Stud Assembly 2017 EMP, Inc. 11
Explanation of Function Component Greasing NOTE: See Service Bulletin: Approved Grease 9910039075 for a list of dielectric grease products that have been approved for use in maintenance and service. NOTE: Only use clean dielectric grease. NOTE: FiL-15 fan connectors do not get greased. 1. Apply dielectric grease to each harness side electrical connector and the power and ground studs. See Table 3 below for specified grease amounts. Figure 6 µtmc Connector Table 3 Reference Quantities Grease (Grams) Description 5.00 g Power/Ground Studs (applied directly to stud) 5.00 g Power/Ground Studs with 220 Size Boots* 10.00 g Power/Ground Studs with 232 Size Boots* 1.25 g 11 Fan Connectors 1.00 g µtmc, TMC, CAN Connectors 0.75 g LED/Pushbutton Connector 0.5 g Ignition Connector NONE 15 Fan Connectors NOTE: Use this quantity if filling boot with grease instead of applying directly to stud. 220 size boots have a 1-1/8 diameter opening. 232 size boots have a 1-1/2 diameter opening. NOTE: Dielectric grease should be applied to completely cover all metal (ring terminals, washers, nuts, and studs). It is acceptable for grease to be visible on the outside of the boot. Figure 7 2. Remove any excess grease after proper connections have been made, if needed. Figure 5 FiL-11 Fan Connector 2017 EMP, Inc. 12
Routine Maintenance Frequency When checking/filling vehicle fluids Once per week Every engine oil change Every three months or more often if conditions are harsh* As needed** Annually+ Action Check LED and System operation by activating the Fan Reverse Button Clear debris from heat exchangers by activating the Fan Reverse Button Inspect cooling system for leaks. Sample coolant and check to ensure coolant meets minimum coolant quality requirements. Clean main power and ground stud connectors and apply dielectric grease at both points. (Reference Surface Mount Stud Maintenance) Wash heat exchangers from engine side. Inspect area around the heat exchangers and fan shroud for debris and damage. Check bonding wires (if applicable) for wear or frayed insulation. Ensure all electrical connections are tight. Observe system diagnostic data to act on intermittent fault history. Clear inactive faults. Inspect main power cables for wear or frayed insulation and nylon bushings. Ensure connections are tightened to proper torque rating. Inspect main harness and fan connectors. Ensure all wires and pin connections are intact. Inspect fuses and fuse holders. Inspect support structure for any damage or loose hardware. The EMP radiator is subject to the same corruption from dirt, salt, and other foreign matter which enter the conventional radiator. Cleaning frequency depends on local conditions and should be completed as per normal fleet radiator cleaning. Perform this cleaning once per month during the winter months when salts are applied to roads. Routine Maintenance Minimum Coolant Quality Requirements To protect your heat exchangers from damage or blockages, all coolant should be maintained to meet the requirements of Cummins Service Bulletin #3666132-07 Cummins Coolant Requirements and Maintenance (or more recent revisions). If your system is cooling an engine other than a Cummins engine, follow your engine manufacturer s guidelines, but ensure that you are using an antifreeze with system protection for aluminum components. The Cummins bulletin is freely available on the internet. Surface Mount Stud Maintenance NOTE: Corrosion on power and ground studs can lead to performance issues and possibly create a path for stray voltage to enter the steel frame. 1. Locate the power and ground studs on the assembly. Pull boots back from surface mount stud. 2. Wipe grease and any debris from the ring terminal and stud area. Observe if the grease was discolored. If the grease is discolored, thoroughly degrease the area before proceeding. 3. Examine the assembly and if corrosion is found, disassemble the ring terminal from the stud and clean the ring terminals and studs with a brass wire brush. Replace any hardware that shows signs of accelerated corrosion. Reassemble and torque per specification. 4. Apply dielectric grease to power and ground studs per Component Greasing Section. Ensure that the protective boots are installed over the stud assemblies. ** Report creation is at the discretion of the fleet maintenance department. + Inspections should also be conducted after any service to the unit. Figure 8 2017 EMP, Inc. 13
System Pinouts System Pinouts Figure 9 2017 EMP, Inc. 14
System Mounting Hole Locations System Mounting Hole Locations Figure 10 2017 EMP, Inc. 15
Wiring Schematic Wiring Schematic 2017 EMP, Inc. 16
Wire Harness Schematic - 3170031019
Wire Harness Schematic - 3170031019