EMP TK3-2932 Bedienungsanleitung

Rev

Rev By

Date

Description of Change

Approved By

SRS

10/18/17

New Release

ECN4822

8/27/21

Revisions

ECN7342

Quick Start Guide

TK3/TK4 Cooling System and

Fan Shroud Assemblies

Models TK3-2932, TK4-2932 and SO4-2932

This quick start guide is effective for consumer installations of the part numbers listed in

System Part Numbers. OEM installers must contact EMP for production requirements.

Product Overview

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.

Engineered Machined Products Inc.

2701 North 30th 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.

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 part number.

Table of Contents

Product Overview ..............................................................................................................................................2

Introduction........................................................................................................................................................4

Purpose .........................................................................................................................................................4

Service Technician Responsibilities ...............................................................................................................4

Liability Disclaimer .........................................................................................................................................4

Additional Information ....................................................................................................................................4

Routine Maintenance .....................................................................................................................................4

Technical Help ...............................................................................................................................................4

About This Document ........................................................................................................................................5

Warnings, Cautions and Notes.......................................................................................................................5

Definition of Terms.........................................................................................................................................5

Product Safety Warnings ...................................................................................................................................6

System Part Numbers .......................................................................................................................................7

Explanation of Function .....................................................................................................................................8

System Schematic .........................................................................................................................................8

FIL11 Fans and μTMC System Controller ......................................................................................................8

Diagnostic Lamp ............................................................................................................................................8

Service Tool Interface ....................................................................................................................................9

Installation .......................................................................................................................................................10

Mounting Hole Locations.............................................................................................................................. 10

Power and Ground Stud Assembly ..............................................................................................................10

Minimum Coolant Quality Requirements ...................................................................................................... 10

System Connection Pinouts ......................................................................................................................... 11

Connector Greasing .....................................................................................................................................11

Troubleshooting...............................................................................................................................................12

EMP Simple Service Tool.............................................................................................................................12

Reading Diagnostic Codes...........................................................................................................................12

Wiring Schematic........................................................................................................................................... A-1

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 part number.

Service Technician Responsibilities

Ensure that all safety messages and information messages are read and understood before installation,

maintenance, or repairs are performed. It is important to use caution when service work is performed. Knowledge

of impacted systems and their 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.

Additional Information

Access https://www.emp-corp.com/support/ for service software, service bulletins, service manuals, service

drawings, and other documents related to your installed EMP systems and components. First time users may

create a free customer login at http://www.emp-corp.com/account/register/.

Routine Maintenance

Routine maintenance schedule and procedures are outlined in service bulletin 9910039031.

Technical Help

Contact EMP Customer Service for technical help at +1 (906) 789-7497 or service@emp-corp.com.

About This Document

Warnings, Cautions and Notes

Two headings are used in this document to stress your safety and safe operation of the system. They are styled

with a graphic bullet and bold, uppercase text: WARNING and CAUTION. Warnings highlight risks to

personnel — hazards, unsafe conditions and practices that can result in personal injury or death. Cautions

indicate conditions or practices that can cause damage to components, systems, or other equipment.

A third heading, styled as NOTE, calls attention to additional information about components and procedures

discussed in the document.

Definition of Terms

EMP-Link...... EMP LIN based proprietary serial data bus.

FIL11............. 11” fan with integral controller and EMP-Link communication.

JW................. Jacket water.

LED ............... Light emitting diode.

µTMC ............ Micro thermal management controller.

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 repairs are performed. It is important to use caution when service work is

performed. Knowledge of impacted systems and their operation are important before the removal or

disassembly of any component.

WARNING: Make sure the equipment cannot move before doing any work or diagnostic procedures on

the EMP component, system, or vehicle.

WARNING: When working near electric components, ensure they cannot activate unexpectedly.

Remove power or utilize lock out switches.

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.

WARNING: Make sure all tools, parts and service equipment are removed from the work area.

WARNING: Ensure that all system power and ground connection points are torqued to EMP and/or

OEM specifications to prevent system damage. Failure to follow specified torque requirements can result in

loose connections which can damage electronic components and will void EMP warranty.

System Part Numbers

TK4 Shroud Only Part Numbers

Part Number

Serial Number

Model

Voltage

1940031016

All

TK4

12V

1940031026

All

TK4

24V

1940031050

All

TK4

12V

1940031051

All

TK4

24V

1940031052

All

TK4

12V

1940031053

All

TK4

24V

1940031062

All

TK4

12V

1940031063

All

TK4

24V

1940031064

All

TK4

12V

1940031065

All

TK4

24V

1940031066

All

TK4

12V

1940031067

All

TK4

24V

TK3 and TK4 with Heat Exchanger Part Numbers

Part Number

Serial Number

Model

Voltage

2020031007

All

TK4

12V

2020031020

All

TK3

12V

2020031021

All

TK4

24V

2020031022

All

TK3

24V

2020031054

All

TK4

12V

2020031055

All

TK3

12V

2020031056

All

TK4

24V

2020031057

All

TK3

24V

2020031058

All

TK4

12V

2020031059

All

TK3

12V

2020031060

All

TK4

24V

2020031061

All

TK3

24V

2020031068

All

TK3

12V

2020031069

All

TK3

24V

2020031070

All

TK4

12V

2020031071

All

TK4

24V

2020031072

All

TK4

12V

2020031073

All

TK3

12V

2020031074

All

TK4

24V

2020031075

All

TK3

24V

2020031076

All

TK4

12V

2020031077

All

TK3

12V

2020031078

All

TK4

24V

2020031079

All

TK3

24V

Explanation of Function

System Schematic

Optional Pushbutton

3-pin EMP-Link

Diagnostic Connector

12V or 24V

Ignition Enable

12V or 24V

Power

Ground

µTMC

Fan 1

Fan 3 Fan 4

Fan 2

EMP-Link

Diagnostic Lamp

Air Temp

Sensor

Coolant Temp

Sensor

NOTE: The TK3 systems use the same harness as the TK4 systems. The fan 1 connector on the harness for

TK3 systems is capped.

FIL11 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 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 FIL11 fans on 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 FIL11 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 FIL11

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 FIL11 fans to report status information

back to the μTMC system controller for enhanced diagnostics.

The μTMC commands fan speed by referencing the inputs from the coolant and air temperature thermistors.

When either or both of the thermistors report a temperature above the programmed thresholds, the μTMC

controller will command the appropriate fans to a speed based on the set points for the coolant and the air.

Diagnostic Lamp

The diagnostic lamp will blink out active diagnostic codes. Active diagnostic codes indicate an abnormal condition

that persists over time. See Troubleshooting for information about reading diagnostic codes from the cooling

system.

Explanation of Function

Service Tool Interface

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.

Installation

Mounting Hole Locations

Power and Ground Stud Assembly

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.

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.

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