EMP Refuse Gen IV Mini-Hybrid User manual

Quick Start Guide
Refuse Gen IV Mini-Hybrid®
Cooling Systems
Service drawings for this manual can be obtained at www.emp-corp.com/support/documents
by searching for the system’s part number.
Rev
Rev By
Date
Description of Change
Approved By
A
JRB
07/26/16
New Release
ECN4325
B
SRS
08/02/19
Revisions
ECN5314
9970039096_Rev. B - 8/2/2019 © 2016 EMP, Inc. 1

Product Overview
Engineered Machined Products, Inc.
2701 North 30th Street
Escanaba, MI, USA 49829
Phone: [phone]
www.emp-corp.com
[e-mail]
Product Overview
The EMP Mini-Hybrid® Cooling System is a revolutionary advanced thermal product designed for heavy duty
vehicles. The Mini-Hybrid system is ideal for retrofitting/refurbishing existing fleets. Benefits include better fuel
economy and lower maintenance costs. EMP’s Mini-Hybrid system uses proprietary precision cooling
algorithms to manage cooling needs of engines and AC systems. The strategy employed maintains
temperatures within an ideal range for operation.
Each Mini-Hybrid system contains variable-speed electric fans and an EMP TMC™ system controller. The
assembly replaces the OEM mechanical fan and shroud and is designed to fit on the OEM radiator. There is no
need to replace the radiator or charge air cooler. The system is available in configurations for each truck
model.
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.
© 2016 EMP, Inc. 2

Table of Contents
Table of Contents
PRODUCT OVERVIEW........................................................................................................................................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
EXPLANATION OF FUNCTION...........................................................................................................................6
SYSTEM INTERFACES.......................................................................................................................................7
J1939 CAN Communications............................................................................................................................7
AC Control.........................................................................................................................................................7
Ignition Source..................................................................................................................................................8
USER/MAINTENANCE INTERFACES.................................................................................................................8
Push Button Reverse........................................................................................................................................8
On-Board Diagnostic Notification......................................................................................................................9
EMP Service Suite ..........................................................................................................................................10
TECHNICAL HELP.............................................................................................................................................12
FINAL AUDIT/WARRANTY................................................................................................................................12
PRODUCT WARRANTY REGISTRATION FORM.............................................................................................13
© 2016 EMP, Inc. 3

Introduction
Introduction
Purpose
The purpose of the Quick Start Manual is to present basic information and procedures required to properly
service and maintain your Mini-Hybrid cooling system. Complete documentation is available in Service
Manuals, Service Drawings and Troubleshooting documents located on the EMP Website at www.emp-
corp.com.
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 Mini-Hybrid 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 Mini-Hybrid 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
TMC = Thermal Management Controller
FIL11™ = 11” Fan with Integral Controller and EMP-Link Communications
FIL15™ = 15” Fan with Integral Controller and EMP-Link Communications
EMP-Link™ = EMP LIN Based Propriety Serial Data Bus
© 2016 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 vehicle is in neutral, the parking brake is set, and the wheels are blocked
before doing any work or diagnostic procedures on the Mini-Hybrid® system or vehicle.
WARNING: Disconnect the 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 vehicle.
WARNING: Make sure all tools, parts, and service equipment are removed from the engine
compartment and vehicle after all work is done.
WARNING: 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 Mini-Hybrid® and will void EMP warranty.
© 2016 EMP, Inc. 5

Explanation of Function
Explanation of Function
The Mini-Hybrid system (see Figure 1) consists of
variable-speed electric fans and an EMP TMC
system controller. The Mini-Hybrid system replaces
the OEM mechanical fan and shroud, while
mounting directly to the OEM radiator with no need
to replace the radiator or charge air cooler.
Powering the Mini-Hybrid system
The Mini-Hybrid system configuration varies by
vehicle make, model, and year.
•Each FIL15 fan can draw up to 70 Amps.
•Each FIL11 fan can draw up to 30 Amps.
•The OEM alternator must be replaced with a
high-output alternator. EMP will provide
recommendations.
•Wire and alternator sizing must be suitable
for a maximum power draw scenario.
However, Mini-Hybrid systems rarely draw
maximum power in day-to-day operations.
Controlling the Mini-Hybrid system
Fan speeds are controlled automatically by the
EMP TMC system controller using three inputs:
1. Engine coolant temperature controls fan
speeds based on temperature reported by the
ECU over J1939 CAN.
2. Intake manifold temperature controls fan
speeds based on temperature reported by the
ECU over J1939 CAN.
3. The air conditioning high-pressure fan switch
controls fan speeds based on AC system
pressure measured via hardwire to the
pressure switch.
Fans can be manually reversed to backflush dust
and debris from the cooling system. Fan reversal is
controlled via a momentary pushbutton located
inside the cab. Push and release the button to
activate a fan reversal.
Power consumed by the Mini-Hybrid system is
minimized by running fans only as fast as
necessary to maintain inputs at optimal values.
Power consumption is also reduced through
individual control of fans. For example, if two fans
have coverage of the AC condenser, only those two
fans will run when AC system pressure requires air
flow. In daily operations on refuse vehicles, Mini-
Hybrid systems consume less than 0.5 hp on
average.
Figure 1 - Mini-Hybrid System for 2013 Peterbilt 320
© 2016 EMP, Inc. 6

System Interfaces
System Interfaces
J1939 CAN Communications
Engine coolant and intake manifold temperature
inputs from the ECU are acquired by installing an
adapter harness in the existing vehicle CAN wiring.
The EMP CAN adapter harness is located under
the dash panels or in the engine compartment on
most trucks (see Figure 2).
Figure 2
AC Control
Air conditioning input is obtained by wiring directly
to the existing AC system high-pressure fan switch
(see Figure 3).
Figure 3
© 2016 EMP, Inc. 7

System Interfaces/User/Maintenance Interfaces
Ignition Source
Mini-Hybrid systems require a key-activated (on/off)
ignition source at battery voltage.
The Mini-Hybrid system obtains ignition input
directly from the key switch. Ignition is fused at 5A
near the ignition source with an automotive-style
MINI fuse (see Figure 4).
Figure 4
User/Maintenance Interfaces
Push Button Reverse
The fan reverse button with integrated notification
lamp is located in the cab (see Figure 5). Push and
release the button to activate a fan reversal. This
function helps to clean debris from the radiator. The
vehicle must be stationary for fan reversal.
The notification lamp will illuminate to indicate that
the reverse cycle has been activated, and after a
short delay the fans will run at max speed in
reverse for 20 seconds. Pressing the button a
second time at any point after reverse cycle
initiation will cancel the reverse cycle.
Figure 5
© 2016 EMP, Inc. 8

User/Maintenance Interfaces
On-Board Diagnostic Notification
The fan reverse button/notification lamp is located in the cab. In the event that the Mini-Hybrid system
experiences a condition that is not remedied in an allotted time, the notification lamp will illuminate.
Active diagnostic codes may be identified using the EMP Service Suite™ tool, EMPower Connect™.
Alternately, a technician may enter “maintenance mode” using the button in the cab. Enter maintenance mode
by pressing the reverse button 4 times in 2 seconds or less.
Read active and pending diagnostic codes from the blinking cab notification lamp (or optional engine
compartment diagnostic lamp if installed).
The format of the diagnostic code is:
XX-YY, where
XX is the first number of the diagnostic code
YY is the second number of the diagnostic code
The diagnostic code is communicated by the lamp as follows:
1. A series of fast blinks indicate the lamp is in maintenance mode.
2. Lamp on for 4 seconds to indicate the start of the diagnostic code list.
3. Off for 2.5 seconds to indicate the start of a single code.
4. A sequence of 0.5 second blinks. The number of these blinks indicates the first number (XX) of the
diagnostic code.
5. Off for 1.25 seconds to indicate the start of the second digit of the diagnostic code.
6. A sequence of 0.5 second blinks. The number of these blinks indicates the second number (YY) of the
diagnostic code.
7. If multiple diagnostic codes are active, the next active diagnostic code will be communicated beginning
with step 3. When all diagnostic codes have been communicated, the diagnostic code list will be repeated
beginning with the series of fast blinks. As an example, Figure 6 illustrates code 02-02, a low battery
warning.
Figure 6
If an active code exists, the Mini-Hybrid system will continue to operate, but perhaps not as expected
depending on the issue (for example fans may run in default).
The engine will only derate or disable if necessary based on ECU measurements of excessive temperature(s).
Diagnostic codes are listed in the troubleshooting manual for the system and are available in the EMP Service
Suite software package available at www.emp-corp.com.
© 2016 EMP, Inc. 9

User/Maintenance Interfaces
EMP Service Suite
When you install EMP Service Suite on your shop computer, several programs and utilities will load and be
saved in a program folder “EMP Tools.” An icon will be placed on your desktop for EMPower Connect, EMP’s
diagnostics and control service tool.
Troubleshooting manuals and diagnostic code definitions are available under the trouble shooting menu.
The best way to learn about the EMP Service Suite is to browse the tutorial located in the help menu of
EMPower Connect. See Figure 7.
Figure 7
© 2016 EMP, Inc. 10

User/Maintenance Interfaces
EMPower Connect provides interactive Mini-Hybrid system trouble shooting and diagnostics. When first
connected to the system, the program will display the diagnostics page which lists out active, inactive and
pending codes as well as providing links directly to the troubleshooting manual from displayed codes (see
Figure 8).
NOTE: Click on Troubleshoot to open the troubleshooting manual for detailed troubleshooting steps (see
Figure 8).
Figure 8
© 2016 EMP, Inc. 11

User/Maint. Interfaces/Tech Help/Final Audit/Warranty
EMPower Connect also has a virtual dashboard (F3 – Dash) which allows system monitoring and manual
controls (see Figure 9).
Figure 9
Technical Help
Contact EMP Customer Service for technical help at [phone] or [e-mail]. Additional
information about this product is located under the support tab of the EMP official website: www.emp-corp.com
Final Audit/Warranty
Mail, Fax, or Email the completed final audit/warranty registration form located at the end of this document to:
EMP Advanced Development, LLC
2701 North 30th Street
Escanaba, MI, USA 49829
FAX# [phone]
[e-mail]
© 2016 EMP, Inc. 12

Product Warranty Registration Form
Product Warranty Registration Form
© 2016 EMP, Inc. 13

Product Registration
Customer Information
Customer/Business Name
Customer Contact Name
Customer Contact E-mail
Customer Contact Phone
Address
City
State/Province
Zip Code
Product Information
Product Type (Complete one form per
product type. For complete thermal
system assemblies you do not need to
register each assembled fan/controller/
pump)
Electric Water Pump
Individual Fan Individual
Controller
EMP Alternator
Oil Pump
OilMate System
Other
Thermal System - # of Fans
Model Purchased
Part Number
Serial Number
Installation Date
9960039049_Rev. E - 01/25/2017

Vehicle Information
Serial, Part, and Model Number are Located on the EMP Product Label
Fleet ID #
Vehicle Make/Model
Vehicle Model Year
Vehicle Identification Number (VIN)
Vehicle Miles/Hours at Installation
If New System, Alternator Serial Number
Notes
Contact EMP
Mail/Fax/E-Mail Completed Registration Forms to:
EMPAdvanced Development, LLC
2701 North 30th Street
Escanaba, MI, USA 49829
FAX: [phone]
E-Mail: [email protected]