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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
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Product Overview/Technical Help
Engineered Machined Products Inc. 2701 North 30th Street
Escanaba, MI, USA 49829 Phone: +1 (906) 789-7497
www.emp-corp.com [email protected]
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 [email protected]. Additional
information about this product is located under the support tab of
the EMP official website: www.emp-corp.com.
Service parts and the full Service Manual for this product can
be obtained at http://www.emp-corp.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
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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
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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
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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
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List of System Part Numbers
List of System Part Numbers for This Manual
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
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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
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Explanation of Function
TK3 and TK4 Schematics
uTMC
12V or 24V
12V or 24V Wakeup Enable
3 Sc e at c
Ground
Power
Diagnostic LED
Controller
Fan3
Fan 1
Fan4
Fan 2
30A
30A
30A
30A
30A 12V or 24V
Gnd
EMP-Link12V or 24V Wakeup Enable
Coolant Temp Sensor
Optional Push Button
Air Temp Sensor
3 Pin EMP-Link Diagnostic Connector
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
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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
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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
Display̲.
Figure 3
© 2017 EMP, Inc. 10
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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
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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.
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 5 – FiL-11 Fan Connector
Figure 6 – µTMC Connector
Figure 7
2. Remove any excess grease after proper connections have been
made, if needed.
© 2017 EMP, Inc. 12
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Routine Maintenance
Routine Maintenance Frequency Action
When checking/filling vehicle fluids
Check LED and System operation by activating the Fan Reverse
Button
Once per week Clear debris from heat exchangers by activating
the Fan Reverse Button
Every engine oil change
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)
Every three months or more often if conditions are harsh*
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.
As needed** Observe system diagnostic data to act on
intermittent fault history. Clear inactive faults.
Annually+ 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.
** Report creation is at the discretion of the fleet maintenance
department.
+ Inspections should also be conducted after any service to the
unit.
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.
Figure 8
© 2017 EMP, Inc. 13
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System Pinouts
System Pinouts
Figure 9
© 2017 EMP, Inc. 14
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System Mounting Hole Locations
System Mounting Hole Locations
Figure 10
© 2017 EMP, Inc. 15
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Wiring Schematic
Wiring Schematic
© 2017 EMP, Inc. 16
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Wire Harness Schematic - 3170031019
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Wire Harness Schematic - 3170031019
Product OverviewTechnical HelpTable of
ContentsIntroductionPurposeService Technician
ResponsibilitiesLiability DisclaimerDefinition of Terms
SafetyWarnings, Cautions & NotesProduct Safety Warnings
List of System Part Numbers for This ManualExplanation of
FunctionFiL-11 Fans and μTMC System ControllerTK3 and TK4
SchematicsDiagnostic LEDService Tool
InterfaceTroubleshootingService ToolPower and Ground Stud Assembly
DetailsComponent Greasing
Routine MaintenanceMinimum Coolant Quality RequirementsSurface
Mount Stud Maintenance
System PinoutsSystem Mounting Hole Locations
Wiring Schematic9980031041_RevC.1.pdfProduct OverviewTable of
ContentsIntroductionPurposeService Technician
ResponsibilitiesLiability DisclaimerDefinition of Terms
SafetyWarnings, Cautions & NotesProduct Safety Warnings
List of System Part Numbers for This ManualExplanation of
FunctionFiL-11 Fans and μTMC System ControllerTK3/TK4 Fan Numbering
Scheme
Diagnostic LEDService Tool InterfaceTroubleshootingService
ToolMain TK3/TK4 System Harness 3170031019
Service Parts ReplacementComponent GreasingFiL-11
FanFusingPower/Ground Stud Replacement Kit (1370090014)Coolant
ThermistorAir Thermistor (If Applicable)Diagnostic LEDPressure
CapMain Wire HarnessHarness RemovalHarness InstallationTK4 Harness
Layout with Harness Fastener LocationsTK3 Harness Layout with
Harness Fastener LocationsPower and Ground Stud Assembly
DetailsBracket Assembly Details
NOTE: Care must be taken to ensure the white wire gets attached
to the red post on the LED. If this is not connected properly, the
LED will not operate.NOTE: The coolant and air thermistor
connectors are keyed so they cannot be incorrectly installed.
Ensure the connector is fully seated.
System ControllerHeat Exchanger Replacement for TK3/TK4Shroud
Replacement for TK3/TK4Controller Bracket Replacement for
TK3/TK4
Routine MaintenanceMinimum Coolant Quality RequirementsCorrosion
PreventionRust RepairPower WashingFan SideHeat ExchangerShroud
Clean-outs (Where Applicable)Surface Mount Stud Maintenance
Technical HelpWiring Schematic9980031041.pdfProduct
OverviewTable of ContentsIntroductionPurposeService Technician
ResponsibilitiesLiability DisclaimerDefinition of Terms
SafetyWarnings, Cautions & NotesProduct Safety Warnings
List of System Part Numbers for This ManualExplanation of
FunctionFiL-11 Fans and μTMC System ControllerTK3/TK4 Fan Numbering
Scheme
Diagnostic LEDService Tool InterfaceTroubleshootingService
ToolMain TK3/TK4 System Harness 3170031019
Service Parts ReplacementConnector GreasingSurface Mount
StudsOther connectors
FiL-11 FanFusingCoolant ThermistorAir ThermistorDiagnostic
LEDPressure CapMain Wire HarnessHarness RemovalHarness
InstallationTK4 Harness Layout with Harness Fastener LocationsTK3
Harness Layout with Harness Fastener LocationsPower and Ground Stud
Assembly DetailsBracket Assembly Details
NOTE: Care must be taken to ensure the white wire gets attached
to the red post on the LED. If this is not connected properly, the
LED will not operate.NOTE: The coolant and air thermistor
connectors are keyed so they cannot be incorrectly installed.
Ensure the connector is fully seated.
System ControllerHeat Exchanger Replacement for TK3/TK4Shroud
Replacement for TK3/TK4Controller Bracket Replacement for
TK3/TK4
Routine MaintenanceMinimum Coolant Quality RequirementsCorrosion
PreventionRust RepairPower WashingFan SideHeat ExchangerShroud
Clean-outs (Where Applicable)Surface Mount Stud Maintenance
Technical HelpWiring Schematic