EMP TK3-2932 User manual

Rev
Rev By
Date
Description of Change
Approved By
A
SRS
10/18/17
New Release
ECN4822
B
ME
8/27/21
Revisions
ECN7342
9970031082 Rev. B – 08/27/2021 © 2017 EMP, Inc. 1
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.
© 2017 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 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
© 2017 EMP, Inc. 3
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
© 2017 EMP, Inc. 4
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 [phone] or [e-mail].

About This Document
© 2017 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
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
© 2017 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.
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
© 2017 EMP, Inc. 7
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
© 2017 EMP, Inc. 8
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
© 2017 EMP, Inc. 9
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
© 2017 EMP, Inc. 10
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.
!

Installation
© 2017 EMP, Inc. 11
System Connection Pinouts
Connector 1 – Ignition Enable
Single pin male (pins) Delphi Weatherpack
connector. Mating connector is female (sockets)
Delphi Weatherpack connector.
Connector 2 – EMP-Link Diagnostic
Connector
3-pin female (sockets) Delphi Metri-Pack 150 series.
Mating connector is male (pins) Delphi Metri-Pack
150 series.
Connector 3 – Air Temperature Sensor
2-pin male (pins) Delphi Metri-Pack 150 series.
Mating connector is female (sockets) Delphi Metri-
Pack 150 series.
Connector Greasing
NOTE: See Service Bulletin Approved Grease,
document 9910039075, for a list of dielectric
grease products that have been approved for use
in maintenance and service.
NOTE: Only use clean dielectric grease.
1. Apply dielectric grease to each harness side
electrical connector and the power and ground
studs. See the table below for specified grease
amounts.
2. Remove any excess grease after proper
connections have been made, if needed.
Reference Quantities
Grease
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
FIL11 Fan Connectors
1.00 g
µTMC Connector
0.75 g
Lamp/Pushbutton Connector
0.5 g
Ignition Enable Connector
*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.
Pin
Description
A
Ignition Enable
Pin
Description
A
Power
B
EMP-Link
C
Ground/EMP-Link return
Pin
Description
A
Air Temperature
B
Air Temperature Return

Troubleshooting
© 2017 EMP, Inc. 12
Troubleshooting
Use EMP Service Suite to communicate with the system, troubleshoot, and obtain diagnostic information.
Software can be obtained at no charge from the EMP website at http://www.emp-corp.com/support/downloads.
EMP Simple 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,
available as a kit from EMP, part number 7500038005.
The Simple Service tool interfaces with the µTMC system controller and displays controller configuration,
diagnostic 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.
Reading Diagnostic Codes
A diagnostic lamp located on the system will give indication of a system problem if detected. This diagnostic
lamp will flash out diagnostic codes while the system is on. The format of a 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 codes are read out in the following manner:
1. Lamp on for 4 seconds to mark the start of the diagnostic code list.
2. Off for 2.5 seconds to indicate the start of a diagnostic code.
3. A sequence of 0.5 second blinks the number of which indicates the first number (XX) of the diagnostic code.
4. Off for 1.25 seconds to indicate the start of the second digit of the diagnostic code.
5. A sequence of 0.5 second blinks the number of which indicates the second number (YY) of the diagnostic
code.
6. If multiple diagnostic codes are active, the next diagnostic code will be communicated beginning with step 2.
When all diagnostic codes have been communicated, the diagnostic code list will be repeated beginning
with the long on time of step 1.
NOTE: The sequence will be repeated until the condition is removed or cleared manually.
Information about diagnostic codes is available in the troubleshooting manual for the system and in the EMP
Service Suite.

Wiring Schematic - 3170031019
A-1© 2017 EMP, Inc.