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