EMP OK1 Manual

Rev
Rev By
Date
Description of Change
Approved By
G
ME
5/19/22
Revisions
ECN7628
H
ME
1/10/23
Revisions
ECN8814
9980029073 Rev. H – 01/10/2023 © 2011 EMP, Inc. 1
Installation and Service Manual
OK1/OK2 Oil Cooler Assembly
This manual is effective for the installation and service of OK1 and OK2 systems
with 11” fans. See System Part Numbers for a complete list of systems.

Product Overview
© 2011 EMP, Inc. 2
Engineered Machined Products Inc.
2701 North 30th Street
Escanaba, MI, USA 49829
Phone: [phone]
www.emp-corp.com
[e-mail]
Product Overview
The EMP OK1/OK2 oil cooling systems are advanced thermal management products designed for applications
requiring cooling of hydraulic oil, system oil, transmission oil, fluid or any other general cooling application using
oil or a similar fluid. Benefits include lower energy consumption, reduced noise, individual fan diagnostics and
improved temperature control. This document defines the installation requirements and service parts
replacement requirements for the OK1 and OK2 system part numbers listed in System Part Numbers.
The installation requirements defined in this document must be followed in order to ensure the proper operation
and service life of OK1 and OK2 thermal systems.

Table of Contents
© 2011 EMP, Inc. 3
Table of Contents
Product Overview ..............................................................................................................................................2
Introduction........................................................................................................................................................4
Purpose .........................................................................................................................................................4
Service Technician Responsibilities ...............................................................................................................4
Liability Disclaimer .........................................................................................................................................4
More Information............................................................................................................................................4
Routine Maintenance .....................................................................................................................................4
Technical Help ...............................................................................................................................................4
Warranty ........................................................................................................................................................4
About This Document ........................................................................................................................................5
Warnings, Cautions and Notes.......................................................................................................................5
Definition of Terms.........................................................................................................................................5
Product Safety Warnings ...................................................................................................................................6
System Configurations.......................................................................................................................................7
Product Identification......................................................................................................................................7
Model Codes..................................................................................................................................................7
Airflow Direction .............................................................................................................................................7
System Part Numbers ....................................................................................................................................8
System Information............................................................................................................................................9
Operation .......................................................................................................................................................9
OK1 ...............................................................................................................................................................9
OK2 .............................................................................................................................................................10
Common Specifications and Operating Limits .............................................................................................. 11
Wiring and Fusing Requirements .................................................................................................................11
Heat Rejection .............................................................................................................................................12
μTMC Controlled Systems ...........................................................................................................................13
Installation .......................................................................................................................................................17
Orientation ...................................................................................................................................................17
Mounting ......................................................................................................................................................18
Plumbing......................................................................................................................................................20
Wiring and Fusing Recommendations..........................................................................................................21
Software Calibration Options........................................................................................................................22
Troubleshooting...............................................................................................................................................22
Service Parts Replacement .............................................................................................................................23
Connector Greasing .....................................................................................................................................23
Fuse Replacement .......................................................................................................................................23
FIL11 Fan ....................................................................................................................................................24
μTMC System Controller.............................................................................................................................. 25
Power/Ground Stud Replacement Kit (1370090014) – (If Required) ............................................................ 26
Main Wire Harness.......................................................................................................................................27
OK1 Harness Installation..............................................................................................................................28
OK2 Harness Installation..............................................................................................................................29
Heat Exchanger Replacement for OK1/OK2 ................................................................................................ 30
Shroud Replacement for OK1/OK2 ..............................................................................................................31
Fluid Thermistor ...........................................................................................................................................32
Service Tool Interface ..................................................................................................................................32
Appendix A – Wiring Schematics.....................................................................................................................33
3170029067.................................................................................................................................................34
3170029068.................................................................................................................................................35
3170029068, Rev D and Later ..................................................................................................................... 36
Appendix B – Operation Manual μTMC System Controller .............................................................................. 37
Product Warranty Registration Form................................................................................................................ 38

Introduction
© 2011 EMP, Inc. 4
Introduction
Purpose
The purpose of this document is to define the installation and service requirements of the OK1 and OK2 system
part numbers that are listed in System Configurations. The requirements defined in this document must be
followed in order to ensure proper operation and service life of OK1 and OK2 thermal systems.
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.
Knowledge of hazards present and risk of injury to the service technician while working on these systems is
critical to personal safety.
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.
More Information
Documents and software referenced in this manual are available for download from the support section of the
EMP website, https://www.emp-corp.com/support/.
Routine Maintenance
Routine maintenance schedule and procedures are outlined in service bulletin 9910039031.
Technical Help
Contact EMP Technical Service for technical help at [phone] or [e-mail].
Warranty
Mail, Fax, or Email the completed warranty registration form at the end of the document to:
EMP Advanced Development, LLC
2701 North 30th Street
Escanaba, MI, USA 49829
Fax: [phone]
[e-mail]

About This Document
© 2011 EMP, Inc. 5
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
CAN .............. Controller area network.
LED ............... Light-emitting diode.
EMP-Link...... EMP proprietary component to component communication network.
µTMC ............ EMP micro thermal management system controller.
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Product Safety Warnings
© 2011 EMP, Inc. 6
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. Knowledge of hazards present and risk of injury to the service technician
while working on these systems is critical to personal safety
WARNING: Ensure that the equipment cannot move before doing any work or diagnostic procedures
on the EMP component, system, or vehicle.
WARNING: When working on or near electrical components, ensure that they have been disconnected
from their energy source, cannot be accidentally re-energized, and verify the system is in a zero energy
state.
WARNING: Use extreme caution when working on systems under pressure (i.e. coolant, hydraulic
fluids, air, fire suppression, etc.).
WARNING: Ensure the work area is ventilated and well lit.
WARNING: Ensure charged fire extinguishers are in the work area.
WARNING: Ensure all safety guards, shields, and covers are reinstalled when tasks are completed.
WARNING: Ensure 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.
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System Configurations
© 2011 EMP, Inc. 7
System Configurations
Product Identification
The system product label, located on the upper left of the fan side on both OK1 and OK2 systems, lists the model
code, system part number, and serial number of the system. The serial number can be used to obtain system
configuration and all information necessary for component replacements.
Each fan has a product label giving the model code, part number, and serial number of the fan. Fans should be
replaced with a matching part number. The serial number can be used to obtain information about the hardware
and software configuration of the fan.
Model Codes
The OK1 and OK2 oil coolers discussed in this manual share 12 model codes indicating the number of fans,
main dimensions, voltage, and certifications of each system.
Model Code
Fans
Dimensions (in)
Voltage (V)
Certification
OK1-1714-12V
1
17x14
12
-
OK1-1714-24V
1
17x14
24
-
OK1-1714-12V C
1
17x14
12
CSA
OK1-1714-24V C
1
17x14
24
CSA
OK1-1714-12V U
1
17x14
12
UL
OK1-1714-24V U
1
17x14
24
UL
OK2-3219-12V
2
32x19
12
-
OK2-3219-24V
2
32x19
24
-
OK2-3219-12V C
2
32x19
12
CSA
OK2-3219-24V C
2
32x19
24
CSA
OK2-3219-12V U
2
32x19
12
UL
OK2-3219-24V U
2
32x19
24
UL
Airflow Direction
Systems are available with pusher or puller fans, and with different control strategies. The system part number
tables in this section give the fan direction (in the description) and control strategy for each part number.

System Configurations
© 2011 EMP, Inc. 8
System Part Numbers
OK1 and OK2 system configurations vary in voltage, control strategy, fan.
12 Volt Part
Number
24 volt Part
Number
Type Control Cert Fan
2020029049
2020029050
OK1
μTMC
-
Pull
2020029051
2020029052
OK1
μTMC
-
Push
2020029150*
-
OK1
μTMC
-
Push
2020029053
2020029054
OK1
R20L
-
Pull
2020029055
2020029056
OK1
R20L
-
Push
2020029148*
-
OK1
R20L
-
Push
2020029076
2020029077
OK1
R20L
CSA
Push
2020029078
2020029079
OK1
R20L
CSA
Pull
2020029080
2020029081
OK1
R20L
UL
Push
2020029082
2020029083
OK1
R20L
UL
Pull
2020029084
2020029085
OK1
μTMC
CSA
Push
2020029086
2020029087
OK1
μTMC
CSA
Pull
2020029088
2020029089
OK1
μTMC
UL
Push
2020029090
2020029091
OK1
μTMC
UL
Pull
2020029125
2020029126
OK1
R20C
-
Push
2020029127
2020029128
OK1
R20C
-
Pull
2020029058
2020029059
OK2
μTMC
-
Pull
2020029060
2020029061
OK2
μTMC
-
Push
2020029062
2020029063
OK2
R20L
-
Pull
2020029064
2020029065
OK2
R20L
-
Push
2020029093
2020029094
OK2
μTMC
CSA
Pull
2020029095
2020029096
OK2
μTMC
CSA
Push
2020029097
2020029098
OK2
μTMC
UL
Pull
2020029099
2020029100
OK2
μTMC
UL
Push
2020029101
2020029102
OK2
R20L
CSA
Pull
2020029103
2020029104
OK2
R20L
CSA
Push
2020029105
2020029106
OK2
R20L
UL
Pull
2020029107
2020029108
OK2
R20L
UL
Push
2020029121
2020029122
OK2
R20C
-
Pull
2020029123
2020029124
OK2
R20C
-
Push
* 2020029148 and 2020029150 have the fluid inlet and outlet oriented opposite the fan.

System Information
© 2011 EMP, Inc. 9
System Information
Operation
Systems with a μTMC provide temperature-based fan speed control. A harness connects the μTMC and fans
and provides power, ground, a connector for an optional on-board diagnostic lamp/pushbutton and a connector
for interfacing with service tools. Reference Appendix B, Operation Manual μTMC System Controller for more
information. For assistance with system calibrations or settings please contact EMP Technical Service at
[e-mail] and provide a serial number for the part in question.
For information about interfacing with and operating the fans on systems with R20L and R20C control strategy,
refer to Service and Installation Manual 11 Inch Axial Fan Assembly, EMP document 9980036021.
OK1
Maximum current consumption 25 amps
Ignition enable switched 9–32 volt source
Overall package length 16.5 inches
Overall package width 14 inches
Overall package depth 9 inches
Weight (without fluid) 33 pounds
SAE O-ring port size -16
Inlet and outlet thread size 1 5/16-12 UN
Maximum pressure drop in cooler 8 psi
@ 30 mm2/sec and 30 gpm
Heat exchanger volume 0.6 gallons
μTMC Controlled Systems
Harness assembly 3170029067
Fan 1 address resistance Open

System Information
© 2011 EMP, Inc. 10
OK2
Maximum current consumption 50 amps
Ignition enable switched 9–32 volt source
Overall package length 32 inches
Overall package width 19 inches
Overall package depth 10 inches
Weight (without fluid) 75 pounds
SAE O-ring port size -20
Inlet and outlet thread size 1 5/8-12 UN
Maximum pressure drop in cooler 12 psi
@ 30 mm2/sec and 30 gpm
Heat Exchanger Volume 0.8 gallons
μTMC Controlled Systems
Harness assembly 3170029068
Fan 1 address resistance: Open
Fan 2 address resistance: Short