Service Manual

Service Manual
Mini-HybridTM TMC/FiL-11 MH8–5031/5034/4336
This service manual is effective for aftermarket and OEM installations of the TMC/FiL-11
Version of the 5031, 5034 and 4336 MH8 kits.
Part Serial Number

Number
All
9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8

________________________
EMP
2701 North 30th Street

Escanaba, Michigan 49837
Phone: 906-789-7497
www.emp-corp.com
Product Overview
The EMP Mini-HybridTM Thermal Kit is a revolutionary advanced thermal product designed for
transit buses. The Mini-Hybrid is ideal for retrofitting/refurbishing existing transit fleets.
Benefits include better fuel economy, lower maintenance costs, improved safety by elimination
of hydraulic leaks or fires, and reduced emissions of greenhouse gasses.
The information contained in this manual is updated periodically. While great care is taken in compiling the information contained in this manual, EMP
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. EMP reserves the right to change the
content of this manual at anytime without notice.
9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 2

________________________

________________________ Table of Contents
Table of Contents
PRODUCT OVERVIEW ........................................................................................................................................................................2
TABLE OF CONTENTS ........................................................................................................................................................................4
INTRODUCTION ...................................................................................................................................................................................8
PURPOSE ................................................................................................................................................................................................8
SERVICE TECHNICIAN RESPONSIBILITIES ...............................................................................................................................................8
LIABILITY DISCLAIMER..........................................................................................................................................................................8
DEFINITION OF TERMS......................................................................................................................................................................8
SAFETY....................................................................................................................................................................................................9
WARNINGS, CAUTIONS & NOTES ...........................................................................................................................................................9
PRODUCT SAFETY WARNINGS ...............................................................................................................................................................9
EXPLANATION OF FUNCTION .......................................................................................................................................................10
FIL-11 FANS AND TMC SYSTEM CONTROLLER ...................................................................................................................................10
CAN BUS INTERFACE CABLE ..............................................................................................................................................................12
IGNITION CABLE ASSEMBLY ................................................................................................................................................................12
FAN REVERSAL PUSH BUTTON AND DIAGNOSTIC LED ........................................................................................................................12
DIAGNOSTIC LED ................................................................................................................................................................................13
MAIN MH8 KIT HARNESS ....................................................................................................................................................................14
SERVICE PARTS REPLACEMENT..................................................................................................................................................17
FIL-11 FAN ..........................................................................................................................................................................................17
COOLANT THERMISTOR .......................................................................................................................................................................18
CAC THERMISTOR ...............................................................................................................................................................................18
MAIN WIRE HARNESS ..........................................................................................................................................................................21
POWER/GROUND PASS THROUGH STUDS .............................................................................................................................................23
KIT FUSES ............................................................................................................................................................................................24
TMC SYSTEM CONTROLLER ................................................................................................................................................................25
DIAGNOSTIC LED BULB REPLACEMENT ..............................................................................................................................................26
FAN REVERSAL SWITCH/LED DIAGNOSTIC HARNESS REPLACEMENT .................................................................................................26
DRAIN VALVE ......................................................................................................................................................................................27
CROSS BRACE SUPPORT .......................................................................................................................................................................27
RADIATOR SUPPORT ROD AND MOUNTING PLATE ...............................................................................................................................28
DOOR SEAL ..........................................................................................................................................................................................29
CHARGE AIR COOLER/ RADIATOR REPLACEMENT FOR MH8-5031/5034 ............................................................................................30
POWER STEERING RESERVOIR .............................................................................................................................................................31
RADIATOR REFURBISHMENT........................................................................................................................................................32
AIRSIDE CLEANING (EXTERIOR OF RADIATOR).....................................................................................................................................33
WATERSIDE CLEANING (INTERIOR OF RADIATOR)................................................................................................................................33
FIN COMBING.......................................................................................................................................................................................33
DIAGNOSTIC CODES .........................................................................................................................................................................34
TROUBLESHOOT FAULT CODE 01-04 ...................................................................................................................................................36
TROUBLESHOOT FAULT CODE 01-NN..................................................................................................................................................42

TROUBLESHOOT FAULT CODE 07-08 ................................................................................................................................................... 68
TROUBLESHOOT SYSTEM WAKEUP ......................................................................................................................................................84
TROUBLESHOOT SYSTEM POWER .........................................................................................................................................................86
TROUBLESHOOT TMC WAKEUP ..........................................................................................................................................................88
TROUBLESHOOT FIL-11 FAN WAKEUP ................................................................................................................................................90
TROUBLESHOOT FIL-11 FAN COMMUNICATION ..................................................................................................................................91
TROUBLESHOOT TMC POWER .............................................................................................................................................................93
TROUBLESHOOT FIL-11 FAN POWER ...................................................................................................................................................95
TROUBLESHOOT HIGH VOLTAGE .........................................................................................................................................................97
TROUBLESHOOT LOW VOLTAGE ..........................................................................................................................................................99
TROUBLESHOOT VEHICLE J1939 CONNECTION.................................................................................................................................. 101
TROUBLESHOOT HIGH COOLANT TEMPERATURE............................................................................................................................... 103
TROUBLESHOOT LOW COOLANT TEMPERATURE ............................................................................................................................... 105
TROUBLESHOOT INCORRECT COOLANT TEMPERATURE ..................................................................................................................... 107
TROUBLESHOOT COOLANT SENSOR MEASUREMENT ......................................................................................................................... 109
TROUBLESHOOT HIGH INTAKE AIR TEMPERATURE ........................................................................................................................... 111
TROUBLESHOOT CHARGE AIR SENSOR MEASUREMENT .................................................................................................................... 113
TROUBLESHOOT HIGH TRANSMISSION TEMPERATURE ...................................................................................................................... 115
TROUBLESHOOT FAN SLOW OR NOT OPERATING .............................................................................................................................. 116
TROUBLESHOOT A FAN RUNNING AT HIGH SPEED ............................................................................................................................ 118
TROUBLESHOOT JW FANS RUNNING AT HIGH SPEED........................................................................................................................ 119
TROUBLESHOOT CAC FANS RUNNING AT HIGH SPEED ..................................................................................................................... 121
TROUBLESHOOT FAN RUNS WHEN IGNITION OFF .............................................................................................................................. 123
TROUBLESHOOT FAN RUNS WHEN ENGINE OFF ................................................................................................................................ 125
TROUBLESHOOT TMC NOT FUNCTIONING......................................................................................................................................... 127
TROUBLESHOOT SYSTEM NOT FUNCTIONING .................................................................................................................................... 129
TROUBLESHOOT LED NOT FUNCTIONING ......................................................................................................................................... 130

TROUBLESHOOT PUSHBUTTON NOT FUNCTIONING ............................................................................................................................ 132
TROUBLESHOOT LED FLASHING ....................................................................................................................................................... 134
TROUBLESHOOT J1939 DIAGNOSTIC PORT WIRING ........................................................................................................................... 135
TROUBLESHOOT SERVICE TOOL COMMUNICATION............................................................................................................................ 136
TROUBLESHOOT UN-COMMANDED FAN REVERSAL .......................................................................................................................... 138
DIAGNOSTIC PROCEDURES ............................................................................................................................................................ 139
CHECK BATTERY VOLTAGE ............................................................................................................................................................... 140
CHECK FIL-11 ADDRESS RESISTANCE ............................................................................................................................................... 141
CHECK FIL-11 POWER VOLTAGE ....................................................................................................................................................... 142
CHECK FIL-11 WAKEUP VOLTAGE .................................................................................................................................................... 143
CHECK TMC POWER VOLTAGE ......................................................................................................................................................... 144
CHECK TMC WAKEUP VOLTAGE ...................................................................................................................................................... 145
CHECK CONTROLLER FUSE ................................................................................................................................................................ 146
PERFORM TEST DRIVE ....................................................................................................................................................................... 147
CHECK FIL-11 FAN OPERATION ........................................................................................................................................................ 148
CHECK DEFAULT FAN OPERATION .................................................................................................................................................... 149
TEST MAXIMUM FAN PERFORMANCE ................................................................................................................................................ 150
CHECK SYSTEM WAKEUP VOLTAGE .................................................................................................................................................. 151
CHECK SYSTEM VOLTAGE ................................................................................................................................................................. 152
CHECK SYSTEM GROUND CONTINUITY.............................................................................................................................................. 153
CHECK SYSTEM FUSE ........................................................................................................................................................................ 153
CHECK SYSTEM WAKEUP NOT SHORTED TO POWER ......................................................................................................................... 154
TEST THERMOSTAT OPERATION ........................................................................................................................................................ 155
CHECK VEHICLE WAKEUP SOURCE VOLTAGE ................................................................................................................................... 156
CHECK VEHICLE J1939 CONTINUITY ................................................................................................................................................. 157
CHECK TMC J1939 CONTINUITY ....................................................................................................................................................... 158
CHECK FIL-11 EMP-LINK CONTINUITY ............................................................................................................................................ 159
CHECK IF TMC IS OPERATING ........................................................................................................................................................... 160
CHECK TMC J1939 COMMUNICATION .............................................................................................................................................. 162
TEST TMC COOLANT INPUT CIRCUIT ................................................................................................................................................ 163
TEST TMC CHARGE AIR INPUT CIRCUIT ........................................................................................................................................... 164
VERIFY J1939 COOLANT TEMPERATURE RECEIVED .......................................................................................................................... 165
COMPARE COOLANT MEASUREMENTS ............................................................................................................................................... 166
INSPECT AIR FLOW PATH FOR OBSTRUCTIONS .................................................................................................................................. 167
CHECK COOLANT LEVEL ................................................................................................................................................................... 167
CHECK COOLANT MIXTURE ............................................................................................................................................................... 167
CHECK COOLING SYSTEM DEAERATION ............................................................................................................................................ 168
CHECK TRANSMISSION FLUID LEVEL................................................................................................................................................. 168
INSPECT FIL-11 CONNECTOR POWER PINS ........................................................................................................................................ 169
INSPECT FIL-11 WAKE UP PIN ........................................................................................................................................................... 170
INSPECT FIL-11 CONNECTOR COMMUNICATION PINS ........................................................................................................................ 171
INSPECT ADDRESS RESISTOR CONNECTOR ........................................................................................................................................ 172
INSPECT TMC SENSOR CONNECTOR .................................................................................................................................................. 173
INSPECT TMC POWER CONNECTIONS ................................................................................................................................................ 174
INSPECT TMC WAKE UP PIN ............................................................................................................................................................. 173
INSPECT TMC COMMUNICATION CONNECTOR .................................................................................................................................. 176
INSPECT CHARGE AIR SENSOR CONNECTOR ...................................................................................................................................... 177
INSPECT PUSHBUTTON LED CONNECTOR .......................................................................................................................................... 178
INSPECT DIAGNOSTIC CONNECTOR .................................................................................................................................................... 179
INSPECT CHARGING SYSTEM CONNECTIONS ...................................................................................................................................... 180
CHECK CONTROLLER ENVIRONMENTAL CONDITIONS ....................................................................................................................... 180
INSPECT COOLANT SENSOR CONNECTOR ........................................................................................................................................... 181
INSPECT HEAT EXCHANGER FOR CLEANLINESS ................................................................................................................................. 182
INSPECT INTAKE AIR FOR LEAKS ....................................................................................................................................................... 183
INSPECT RECIRCULATION PREVENTION ............................................................................................................................................. 183

INSPECT SYSTEM J1939 CONNECTOR................................................................................................................................................. 184
INSPECT SYSTEM WAKEUP CONNECTOR ............................................................................................................................................ 185
INSPECT FUSE HOLDER ...................................................................................................................................................................... 186
INSPECT LUG CONNECTIONS .............................................................................................................................................................. 187
CHECK CHARGE AIR SENSOR RESISTANCE ........................................................................................................................................ 188
CHECK CHARGE AIR SENSOR HARNESS CONTINUITY ........................................................................................................................ 189
CHECK LOCATION OF CHARGE AIR SENSOR ...................................................................................................................................... 190
CHECK COOLANT SENSOR RESISTANCE ............................................................................................................................................. 191
CHECK COOLANT SENSOR HARNESS CONTINUITY............................................................................................................................. 192
TEST PUSHBUTTON ............................................................................................................................................................................ 193
CHECK PUSHBUTTON CONTINUITY .................................................................................................................................................... 194
CHECK PUSHBUTTON CONTINUITY THROUGH MAIN HARNESS ......................................................................................................... 195
CHECK PUSHBUTTON FOR INTERFERENCE ......................................................................................................................................... 196
READ FAULT CODE FROM LED ......................................................................................................................................................... 197
TEST LED OPERATION....................................................................................................................................................................... 198
CHECK TMC LED OUTPUT ............................................................................................................................................................... 199
TEST LED SOCKET VOLTAGE ............................................................................................................................................................ 200
VERIFY LED POLARITY ..................................................................................................................................................................... 201
CHECK MAIN WIRING HARNESS LED VOLTAGE ............................................................................................................................... 202
CHECK DIAGNOSTIC CONNECTOR J1939 CONTINUITY....................................................................................................................... 203
CHECK DIAGNOSTIC CONNECTOR VOLTAGE ..................................................................................................................................... 204
INSPECT FANS .................................................................................................................................................................................... 205
CHECK ENGINE COMMUNICATION ..................................................................................................................................................... 206
CHECK TRANSMISSION COMMUNICATION ......................................................................................................................................... 207
CHECK ENGINE ECU COOLANT MEASUREMENT ............................................................................................................................... 208
CHECK TRANSMISSION COOLING REQUEST ....................................................................................................................................... 209
DETERMINE COOLANT SENSOR USED ................................................................................................................................................ 210
DETERMINE INTAKE AIR SENSOR USED ............................................................................................................................................. 211
DETERMINE IF TRANSMISSION FAN COMMAND IS ENABLED ............................................................................................................. 212
DETERMINE IF ENGINE SHUTDOWN IS REQUIRED .............................................................................................................................. 213
DETERMINE IF ENGINE COMMUNICATION IS REQUIRED .................................................................................................................... 214
DETERMINE IF J1939 FAN REVERSAL WAS COMMANDED ................................................................................................................. 215
VERIFY FAN IS NOT OBSTRUCTED ..................................................................................................................................................... 215
CHECK FAULT STATUS INFORMATION ............................................................................................................................................... 216

________________________ Introduction
INTRODUCTION
Purpose
The purpose of the Service Manual is to present information and procedures required to properly
service and maintain your Mini-HybridTM cooling system.
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-HybridTM
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-HybridTM 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
LH = Left Hand
RH = Right Hand
CAC = Charge Air Cooler
JW = Jacket Water
LED = Light Emitting Diode
EMP-Link = EMP LIN Based Propriety Serial Data Bus
TMC = Thermal Management Controller
FiL-11 = 11” Fan With Integral Controller and LIN Communications

________________________ Safety
SAFETY
Warnings, Cautions & Notes
Three types of headings are used in this manual to stress your safety and safe operation of the Mini-
Hybrid. 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
MINI-HYBRID OR THE VEHICLE, OR BOTH.
NOTE:
Is used to provide additional information that requires special attention by the technician.
Product Safety Warnings
Ensure that all safety message and information messages are read and understood before
installation, maintenance, or any repairs are performed. The person who services the product may be
unfamiliar with many of the systems on the product. It is import to use caution when service work is
preformed. Knowledge of the vehicle system and operation are important before the removal or
disassembly of any component.
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 or vehicle.
Disconnect the main negative battery cable and/or switch off the battery disconnect switch first
before installation or servicing.
Use extreme caution when working on systems under pressure (i.e. coolant, hydraulic fluids, air
etc…)
Make sure the work area is ventilated and well lit.
Make sure charged fire extinguishers are in the work area.
Reinstall all safety guards, shields, and covers after servicing the vehicle.
Make sure all tools, parts, and service equipment are removed from the engine compartment and
vehicle after all work is done.
Use extreme caution when working on systems containing fluids which may be hot, corrosive or
hazardous.

________________________ Explanation of Function
Explanation of Function
FiL-11 Fans and TMC System Controller
The fans, fan controllers, and system controller are powered off the vehicle’s 24V electrical system.
Current is related to fan speed with the kit consuming a maximum of 180 amps at full cooling
potential. Each fan is fused at 30A and the system controller at 5A. The kit receives power through
two studs mounted to the left side on MH8-5031/5034 kits or the top right side on MH8-4336 kits.
The red stud is for +24V and the black stud for ground. The wake-up line (ignition enable) is a 24V
switched power source sent from the chassis or PLC to initiate operation of fans and system
controllers. The MH8 is also connected to the vehicle’s SAE J1939 data link and a fan reversal
switch/diagnostic LED.
Each of the eight FiL-11 brushless fans within the MH8 kit contain an internal controller. The function
of the built in controller is to control fan speed and direction as commanded via its’ EMP-Link data
bus by the TMC System Controller. If one or more FiL-11 fans loses communications on the EMP-
Link bus when the Ignition enable is on the fan will start go to a default speed until the communication
problem is corrected. Each of the FiL-11 fans are identical and interchangeable however they each
have a unique EMP-Link address that is set by resistors within the MH8 wiring harness. These EMP-
Link addresses allow the FiL-11 fans to report status information back to the TMC System Controller
for enhanced diagnostics. Resistance values for the individual FiL-11 fans are as follows: (See
Figure 1)
FiL-1 Fan # Resistor Value (Ohms)

1 Open
2 0
3 1.1K
4 2.49K
5 4.32K
6 6.65K
7 10.0K
8 15.0K
Figure 1
The FiL-11 fans are controlled by the TMC system controller. The TMC system controller commands
fan speed by referencing the input from the charge air cooler and radiator thermistors along with
information received on the vehicle J1939 CAN bus. When the jacket water or charge air cooler
thermistor detects a temperature above a programmed threshold, the TMC system controller will
command the appropriate fans to a speed based on the high and low temperature set points for the
charge air cooler or radiator. This is done to minimize the amount of electrical power being consumed
by the MH8 for the amount of cooling required for the vehicle. The I/O of the System Controller
includes thermistors to monitor jacket water and charge air cooler system temperatures, a Fan
Reversal Switch Input, an LED output, an Ignition Enable signal and a J1939 CAN Bus to interface to
the eight FiL-11 Fans and also to the vehicle CAN Bus if it is connected. A third thermistor used to
monitor engine compartment temperature is also sometimes installed. A significant part of the TMC
functionality is to implement diagnostics which give indication to the overall status of the MH8 system
and blink out error codes via the red LED if a problem is detected.

Figure 2 - 5031/5034 TMC and FiL-11 Fans
Figure 3 – 4336 TMC and FiL-11 Fans

CAN Bus Interface Cable
The Vehicle CAN interface cable is a cable that ties the MH8 to the vehicle CAN. The interface cable
is composed of a shielded two wire J1939 cable terminated with a 3 pin Deutsch connector on each
end. If the kit is connected as an extension of the J1939 backbone there will also be a Deutsch “Y”
with a 120 ohm termination resistor installed. If the kit is installed as a J1939 node this Deutsch “Y”
will not be present and the 120 ohm termination resistor will be installed elsewhere in the engine
compartment.
Ignition Cable Assembly
The Ignition Cable Assembly is used to signal the MH8 to activate. It is a fused input that is tied to a
vehicle +24 volt line that is present when the Ignition Key is on. The cable assembly consists of two
parts. The first component is a length of 14 AWG GXL wire terminated on one end with a single pin
Delphi Weather-Pack connector and protected with nylon loom. The second component is an in-line
weatherproof fuse holder attached to a 6” length of 14 AWG GXL wire. The end with the Weather-
Pack connector is located on the left hand side of the kit as viewed from the fan side between the
power and ground studs on the MH8-5031/5034 kit and on the upper RH side on the MH8-4336 kit.
Fan Reversal Push button and Diagnostic LED
The fan reversal push button and diagnostic LED are remote located in the engine compartment.
With the ignition enable on and the reversal button is depressed the LED will illuminate, the fans will
reverse for 20 seconds at 5000 RPM, then the fans will restart in forward direction for 10 seconds at
750 RPM to either verify operation and/or assist in cleaning out the charge air cooler and radiator
cores.
The diagnostic LED will flash out blink codes to the technician indicating a problem and minimizing
troubleshooting. The LED will illuminate when the ignition enable line to the MH8 is energized and
will flash codes in the event of an issue with the MH8. A table listing the meaning of the blink codes
can be found in the Error! Reference source not found. section of this document or in the Help
menu of the Service Tool.
Figure 4 - Push Button/LED

Diagnostic LED
A diagnostic LED located on the RH side of the kit will give indication of a system problem if detected.
This diagnostic LED will flash out blink codes to the technician to indicate the source of the fault when
the vehicle is running. The format for the blink fault codes is as follows:
XX-YY where: XX is the first number of the fault code

YY is the second number of the fault code
The blink codes are read out in the following manner:
Warning lamp on for 4 seconds to mark the start of the fault code list
Off for 2.5 seconds to indicate the start of a fault code
A sequence of .5 second blinks the number of which indicates the first number (XX) of the fault code.
Off for 1.25 seconds to indicate the start of the second digit of the fault code.
A sequence of .5 second blinks the number of which indicates the second number (YY) of the fault code.
If multiple fault codes are active, the next fault code will be communicated beginning with step 2. When all
fault codes have been communicated, the fault code list will be repeated beginning with the long on
time of step 1.
The sequence will be repeated until the fault condition is removed or cleared manually
A table listing the meaning of the blink codes can be found in the Appendix or in the Help menu of the
Service Tool.

Main MH8 Kit Harness
The MH8 Main Harness provides power distribution, fuse protection, ground and EMP-Link
communications to the eight FiL-11 Fans Controllers and the TMC System Controller. It also
provides connections to the charge air cooler and jacket water thermistors, diagnostic LED, fan
reversal switch and vehicle CAN bus. Resistors within the harness assembly are used to set the
EMP-Link addresses for the individual FiL-11 Fans. The harness is secured to the MH8 frame
assembly using cable ties with edge clips (See Figure 5 TMC/FiL-11 5031/5034 Edge Clip Locations
and Figure 6 – TMC/FiL-11 4336 Edge Clip Locations) and is protected by rubber grommets at
transitions through the left and right side walls.
Edge Clip
Locations Shown
In Dark Black
Edge Clip
Locations Shown
In Dark Black
Figure 5 – TMC/FiL-11 5031/5034Edge Clip Locations

Edge Clip
Locations Shown
In Dark Black
Edge Clip
Locations Shown
In Dark Black
Figure 6 - TMC/FiL-11 4336 Edge Clip Locations


________________________ Service Parts Replacement
Place the replacement fan onto fan shroud and
SERVICE PARTS orient the same way as removed.
REPLACEMENT NOTE: Pre-coat the last few threads of the (4)

mounting bolts with Loctite 242.
FiL-11 Fan Install the mounting bolts and torque to 106±10

in-lbs using a criss-cross pattern for torque
sequence.
Connect the fan wire harness connector to the
kit wire harness connector and insure that
the locking tabs are fully engaged.
Install tie wrap clips in the locations noted on
removal of the defective fan and attach
main harness to fan shroud using tie straps.
Figure 7 – FiL-11 Fan
WARNING: To avoid serious personal injury,

possible death, or damage to the vehicle,
disconnect the main negative battery terminal
and/or switch off the battery disconnect switch
first before removing or installing any electrical
components.
Disconnect the fan’s connector from the kit wire

harness connector by depressing the
locking tab on the harness connectors and
pulling back on the connector body.
Wiggling the connector body will help in
freeing the connection but do not pull back
using the wire harness since damage to the
wires and/or pin connections could occur.
Clip any tie wraps that are attaching the fan
wire harness to the shroud and take note of
location of tie wrap clips.
Remove all (4) M6 x 16mm fan mount bolts.

CAC Thermistor
Coolant Thermistor
Figure 8 – Coolant Thermistor Figure 9 – CAC Thermistor
WARNING: To avoid serious personal injury, WARNING: To avoid serious personal injury,
possible death, or damage to the vehicle, possible death, or damage to the vehicle,
disconnect the main negative battery terminal disconnect the main negative battery terminal
and/or switch off the battery disconnect switch and/or switch off the battery disconnect switch
first before removing or installing any electrical first before removing or installing any electrical
components. components.
NOTE: The radiator thermistor is located on NOTE: The CAC thermistor is located on the back
radiator on the RH side of the unit as viewed of the unit (Engine side) on either the RH or LH
from the fan side. (See Figure 10 – TMC/FiL-11 sides depending on which side feeds back to the
5031/5034 Radiator Thermistor and Figure 11 – intake of the engine(See Figure 12 - CAC
TMC/FiL-11 4336 Radiator Thermistor) Ensure Thermistor location). The CAC thermistor
the cooling system is completely drained of location must match the calibration to ensure the
coolant. kit operates properly
Disconnect the wire harness connector
attached to the thermistor.
Disconnect the wire harness connector
Using a deep well socket, remove the attached to the thermistor.
thermistor in a counter clockwise rotation.
Using a deep well socket, remove the
Install the new thermistor and torque to 12 ±2 thermistor in a counter clockwise rotation.
ft/lbs. There is pre-applied sealant on the
Install the new thermistor and torque to 1.5 to 2
thermistor threads.
turns past hand tight. There is pre-applied
Re-connect the thermistor wire harness sealant on the thermistor threads.
connector.
Re-connect the thermistor wire harness
Refill the cooling system and check for leaks. connector.

MH8-5031/5034
Radiator Thermistor
Figure 10 – TMC/FiL-11 5031/5034 Radiator Thermistor
MH8-4336 Radiator
Thermistor
Figure 11 – TMC/FiL-11 4336 Radiator Thermistor

CAC Thermistor On Outlet Of

Heat Exchanger (RH or LH Side)
Which Is the Inlet To The Engine
Figure 12 - CAC Thermistor Location

locking tab on the harness and pulling back
Main Wire Harness on the connector body.
9. Disconnect the two Deutsch connectors at
WARNING: To avoid serious personal injury, TMC System controller by depressing the
possible death, or damage to the vehicle, locking tab on the harness connectors and
disconnect the main negative battery terminal pulling back on the connector body.
and/or switch off the battery disconnect switch Wiggling the connector body will help in
first before removing or installing any electrical freeing the connection.
components.
10. Cut the cable ties at each of the edge
Harness Removal: mounted clips on the MH8 frame and on the
FiL-11 Fan shrouds but keep the edge clips
in place since they should be able to be
1. Disconnect the 2 pin Delphi GT150 reused with new tie straps if the clips are
connectors attached to the JW and CAC not damaged.
thermistors by depressing on the locking tab 11. Thread the thermistor connectors, Ignition
at the rear of the connector body and pulling Enable and Vehicle CAN interface
back on the connector body. connectors thru the grommet on the side of
2. Remove the nuts and lock washers securing the kit one at a time.
the main power and ground inputs at the 12. Remove the damaged harness which now
pass thru studs located on the LH side of should now be completely free.
the MH8-5031/5034 kits and upper RH side
of the MH8-4336 kit.
3. Remove the ring terminals from positive and
negative studs noting orientation of both so Harness Installation
that it can be repeated on installation of the
new harness. Examine edge clips mounted to fan shrouds
and replace any that are damaged. Install
4. If the fuse-holder caps located near power new tie straps provided with the harness on
entry are not damaged, remove these caps the edge clips that were not replaced in
by depressing on locking tab and pulling preparation for installation of the new
base away from cap. harness assembly.
5. If the fuse-holder caps are damaged, the Lay harness assembly out across kit as shown
rosebud retainers must be removed to free in the assembly drawing (See Figure 13 -
the caps. Use a straight slot screw driver to TMC/FiL-11 5031/5034 Harness layout and
work underneath the caps and pry the Figure 14 – TMC/FiL-11 4336 Harness
rosebud retainers free. layout).
6. Disconnect Ignition enable input on the Thread the Ignition Enable and Vehicle CAN
single pin Delphi Weather-Pack connector Interface Connector through the hole on the
located on the LH side of the MH8- LH side of the MH8-5031/5034 kits or RH
5031/5034 and upper RH side of the MH8- side on the MH8-4336 kit.
4336.
Thread the JW thermistor connector through
7. Disconnect the Vehicle CAN interface on the hole on the RH side wall of the kit and
the two pin Delphi 150 Metri-Pack connector the CAC thermistor connector the side the
located on the LH side of the kit by lifting the sensor is mounted on.
locking tab and pulling back on the
connector body. Loosely attach harness to edge clip with tie
straps. Allow enough slack to allow harness
8. At each of the eight FiL-11 Fans, disconnect to be moved for adjustment.
the 7 pin Delphi connector attaching the
main kit harness to the fans by lifting the

mounting brackets. If fuse holder covers
are being replaced, attach the holder covers
to the fuse holder mounting brackets using
the rosebud retainers on the back side of
the fuse holders.
Tighten tie straps as harness positioning is
accomplished and clip the excess tie strap
length when complete.
Attach harness to CAC and JW thermistors
along with Ignition Enable and Vehicle CAN
cables insuring locking tabs on all
connectors are engaged.
Figure 13 - TMC/FiL-11 5031/5034 Harness layout
Figure 14 – TMC/FiL-11 4336 Harness layout
Connect the 7 pin Delphi connector at each FiL-

11 fan to the main kit harness insuring that
the locking tabs are fully engaged.
Install the positive and negative ½” ring
terminals to the main power positive and
negative pass thru studs insuring
orientations are the same as on the
removed harness.
Install lock washer and nut onto pass through
studs and torque to 20 ±2 ft/lbs.
Slide protective rubber boot over exposed nut
and end on the positive stud.
If fuse holder covers are being reused, remove
the fuse holder covers on the harness
assembly and plug fuse holder bodies into
the fuse holder covers attached to their

Power/Ground Pass through Studs

components.
Back off the rubber boot on the power/ground
entry side of the kit. Using a ¾” wrench,
remove the nut and lock washer and
remove the ring terminal.
Remove the nut and washer that secures the
main wire harness to the stud on the inside
of the unit and remove ring terminal.
NOTE: Make note of the orientation of the ring
terminals. Replace in the same way as when
removed.
Figure 15 – 5031/5034 Power Stud Assembly
Use a backer wrench on the inside of the unit
and a socket wrench on the outside of the
unit, loosen the stud by turning the socket
wrench in a counter clockwise rotation and
remove the nut.
Pull the inner and outer nylon bushings apart
along with the stud to complete removal.
Insert new stud and slide remaining nylon
bushings with flat washer and nut and
torque to 28 ±2 ft/lbs.
Place all ring terminal of main wire harness
onto stud on inside of unit in the orientation
as noted. Secure with lock washer and nut
and torque to 20 ±2 ft/lbs.
Install main 3/0 SGX cable to outer stud using a
lock washer and nut to secure connection.
Torque nut to 20 ±2 ft/lbs and slide
protective rubber boot over exposed nut and
stud end and insure it is locked onto the
retaining ring.
Figure 16 - 4336 Power Stud Assembly

1 2 3 4 5 6 7 8 TMC
Kit Fuses

components.
NOTE: Each fuse assembly contains three fuses.

Fuse location and assignment is shown in Figure
17 - 5031/5034 Fuse location, Figure 18 -
5031/5034 Fuse Assignment, Figure 19 - 4336
fuse Location and, Figure 20 - 4336 Fuse
Assignment.
Figure 18 - 5031/5034 Fuse Assignment
Remove the fuse holder housing of the TMC/FiL-11 MH8-4336 Fan Numbers
suspected blown fuse by depressing the
locking tab while pulling down on the on the Controller
Fuses
fuse-holder holder base.
1 2 3
Remove the 30 Amp fuse for a fan or 5 Amp
fuse for the TMC by pulling the base away
from fuse holder cap.
4 5
Insert new fuse by pressing into place until fully
seated.
Replace fuse holder base into its’ cover insuring
the locking tab is fully engaged.
6 7 8
Fan Fuses
Figure 19 - 4336 fuse Location

MH8-5031/5034 Fan Numbers
7 8 TMC 4 5 6 1 2 3
4
2
1 3
8
6
5 7
Figure 17 - 5031/5034 Fuse location
Figure 20 - 4336 Fuse Assignment

Clean any dust and debris from the harness
TMC System Controller connectors. Insure the harness connector
electrical sockets remain free of dirt to
insure a solid electrical connection to the
new controller.
Pre-coat the last few threads of the mounting
bolts with Loctite 242.
Mount the new controller to the fan shroud
using the mounting bolts and torque to 12
±2 ft-lbs.
NOTE: Pre-coat the last few threads of the (2)
mounting bolts with Loctite 242.
Connect the wire harness connectors to the
TMC controller and insure that the locking
tabs are fully engaged.
Figure 21 – 5031/5034 TMC System Controller Once the new TMC has been installed it must
be configured for the vehicle using the EMP
Service Tool EMPower Connect.
Figure 22 – 4336 TMC System Controller

components.
Remove the wire harness connections at the

TMS controller by depressing the locking
tab on the harness connectors and pulling
back on the connector body. Wiggling the
connector body will help in freeing the
connection but do not pull back using the
wire harness since damage to the wires
and/or pin connections could occur.
Remove the (2) ¼-20 x 1.00 bolts holding the
TMC controller to the fan shroud.

Diagnostic LED Bulb Replacement Fan Reversal Switch/LED Diagnostic

Harness Replacement
Figure 23 - Fan Reversal/LED Bracket
The Wedge Based LED Bulb is a replaceable Figure 25 - LED Harness

component should it become burned out. To
replace the Bulb:
Grasp the glass bulb and pull straight out while Remove the two screws attaching the
wiggling gently. Switch/LED mounting bracket to the vehicle.
Insert the bulb by aligning the terminals on the Clip the tie straps securing the harness as it
bulb with those on the socket and push routes from the Switch/LED bracket
straight in. The small nub, marked with a assembly to the MH8 kit.
red stripe, on the side of the LED body Disconnect the 4 Pin Delphi150 connector at
marks the positive side and it must be the main harness on the kit and remove the
aligned to the red wire on the holder. Switch/LED harness assembly.
Note: The LED is polarity sensitive and will only Install the replacement harness by
work if installed in the right orientation. The nub reconnecting to the 4 Pin Delphi 150 at the
is marked with a red stripe but is typically on the main kit harness, routing it the same way as
side with the printed number. No damage will the removed unit and re-securing it using tie
occur if the LED is reversed but it will not
straps as it routes to the LED/Push Button
function.
mounting bracket.
Figure 24 - LED Anode Nub

Cross Brace Support
Drain Valve
Drain all the engine coolant from the radiator.
Figure 26 - Drain Valve
NOTE: The drain valve is located on the bottom

left side of the unit as viewed from the fan side.
Figure 27 - Cross Brace
With an open end wrench, remove the valve by
rotating counter clockwise.
Assemble the two brace rods at the center with
Pre-coat the threads of the new valve with pipe a 5/16-18 x 1.0 bolt, washer, and nut with
thread sealant. Install the valve onto the kit the nut facing away from the radiator. Make
in a clockwise rotation and turn 2 to 3 times sure the flanges at the ends of the rods face
from finger tight. the same direction.
Ensure the valve is closed. Refill the system With the cross brace rod end flanges facing
with engine coolant. towards the kit, mount the cross brace to
each corner of the unit with (4) 5/16-18 x 1.0
bolts and torque to 25±4 ft/lbs.

Replace the (2) 7/16-14 x 2 ¾” bolts, flat
Radiator Support Rod and Mounting washers, and locking nuts and torque to 50
Ft/lbs ± 5.
Plate
Figure 28: Upper Support Rod Assembly
Mounting Plate
Remove the (6) lock nuts and washers.
Remove bracket.
Replace the new bracket in the same
orientation as before.
Replace the (6) lock nuts and washers and
torque to 15±1 ft-lbs.
Support Rod
Remove the (2) 7/16-14 x 2 ¾” bolts, flat
washers, and locking nuts.
Remove the radiator support rod.
Adjust the length of the replacement radiator
support rod by turning the threaded rod until
the bolt holes line up with the eyelets on the
vehicle and the radiator.

Door Seal
Figure 29 - Door Seal
For the left and right side door seals, remove

the (3) bolts and remove the door seal.
Replace the door seal lining up the cut out with
the wiring harness pass through grommet.
(See Figure 29 - Door Seal)
Replace the (3) bolts leaving the bolts loose,
adjust to desired position. Torque the bolts
to12±2 ft-lbs.
For the upper and lower door seals, remove the
(5) nuts ans washers then remove door
seals
Replace the door seals and fasten with the (5)
washers and nuts. Leave the nuts loose to
adjust to fit. Torque the nuts to 12±2 ft-lbs.

Gently lift up on the top shell and slide the CAC
Charge Air Cooler/ Radiator out the right side of the kit until completely
removed. (See Figure 30 – 5031/5034CAC
Replacement for MH8-5031/5034 and Radiator)
In the same way, slide the radiator out the right
side until completely removed.
Figure 30 – 5031/5034CAC and Radiator
Figure 32 - Right side shell removed
Figure 31 - 4336 CAC and Radiator
Remove the cross brace. (See Cross Brace

Support)
Remove the radiator thermistor and remove the
charge air thermistor (See CAC Thermistor
Error! Reference source not found.).
Remove the (4) bolts on each side of the unit
that pass through the CAC and the radiator.
NOTE: Note that the left side of the unit (as you Figure 33 - CAC and radiator removed
face the fan side) uses (4) shoulder bolts and the
right side uses (4) shank bolts.
Remove the (8) 5/16-18 x 0.75 bolts on the right To replace the CAC/radiator, first wrap the
side shell of the unit and remove the shell. perimeter of the CAC/radiator with 3/8” x 2”
(See Figure 32 - Right side shell removed) silicone sealing tape. (See Figure 33 - CAC
and radiator removed)

Slide the radiator in from the right side into the
unit until it reaches the opposite side. Power Steering Reservoir
Gently lift up on the top shell and slide the CAC
in until it reaches the opposite side.
Insert the (4) 5/16-18 x 6.0 shoulder bolts
through the CAC/radiator on the left side of
the kit. Leave the nuts loose at this time.
Place the right side shell back onto the unit and
torque the (8) 5/16-18 x .075 mounting bolts
to 25±4 ft/lbs.
Insert the (3) 3/8-16 x 6.0 bolts through the
CAC/radiator. Leave the nuts loose at this
time.
Tighten the nuts on the (4) shoulder bolts on Figure 34 Power Steering Reservoir
the left side and torque to 25±4 ft/lbs.
Tighten the (4) shank bolts on the right side Drain the fluid from the reservoir by removing
torque to 45 ±7 ft/lbs. the plug on the bottom.
Install the radiator and CAC thermistors and Remove all hoses connected to the reservoir.
connect the wire harness.(See CAC Loosen the (2) tank straps holding the reservoir
Thermistor Error! Reference source not and slide the reservoir out.
found.)
Attach cross brace.(See Cross Brace Support) Note: Note the orientation of the tank and it’s
fittings for the replacement install.
Remove the fittings and plug off of the reservoir

and set aside for later.
Remove the (2) bolts fastening the mounting
plate to the frame of the vehicle and remove
the mounting assembly.
To install replacement reservoir
Mount the plate with the mounting holes toward
the front of the vehicle using the (2) bolt
holes that fasten the door stops. (See
Figure 35 - Reservoir mounting plate)

Radiator Refurbishment
The EMP radiator is subject to the same
corruption from dirt, salt and other foreign
matter which enter the conventional radiator.
This corruption as well as bent fins caused by
steam cleaning and pressure washes can
account for a significant reduction of radiator
cooling efficiency. Regular reversal of the
cooling fans will reduce contamination of the
core and the frequency of radiator
refurbishment.
Figure 35 - Reservoir mounting plate
EMP also recommends that service be

Mount the tank straps horizontally with the (4) performed by a qualified heat exchanger shop.
3/8-16 x 0.62. Do not tighten the bolts at this
time. The design of the EMP heat exchanger
Slide the reservoir tank through the tank straps reduces the susceptibility of the heat
and position as previously noted. exchanger to degrade in performance, makes it
Tighten the tank straps down onto the reservoir less susceptible to damage due to pressure
tank. wash and steam cleaning, but also offers
different techniques for the coolant side
Tighten the tank strap mounting bolts. ( See
refurbishment.
Figure 36 - Hydraulic Reservoir Assembly)
The EMP radiator is constructed with an
aluminum “bar-plate” heat exchanger core with
welded tanks. The air side of the core is
designed with a wavy, non louvered fin. The
core is open with only 8.5 fins-per-inch and
unlike conventional tube-and-fin heat
exchangers, the fins are supported to the full
thickness if the tubes reducing the likelihood of
bending and closing.
Figure 36 - Hydraulic Reservoir Assembly

Install the hose fittings and plug using pipe
sealant on the threads and orient as
needed.
Connect all necessary lines (hoses) as
required.
Refill tank with fluid as needed. Check for leaks.

These refurbishment procedures can be easily

performed by a good radiator repair shop.
Performing the air side cleaning procedure
monthly and maintaining the proper 50/50
coolant concentration will preserve radiator
efficiency. The main cause of radiator fin
bending is overly aggressive steam or water
hose cleaning of the radiator.
Airside Cleaning (exterior of radiator)

Figure 37
Soak radiator for 24 hours in a hot (150°F) non-
caustic detergent solution with all fittings
plugged. This will remove the salt, sand,
road oils, brake lining, mud, and tire
rubber/carbon black.
Spray the core with solvent until the fin louvers
are free of dirt.
Wash and air dry. Repaint if necessary.
Waterside Cleaning (interior of

radiator)
Flush the core with a aluminum compatible

system flush solvent.
Wash and air dry.
Fin Combing
Straighten the fins to the original geometry with
Figure 38
needle nose pliers or a fin comb.

______________ Diagnostic Codes Diagnostic Codes
Diagnostic Codes
Fault Type Fault Code Source / Description Explanation: Potential Cause(s):
Internal Temperature Excessively hot environmental conditions.

01 - 04 Overtemperature
Failed internal temperature sensor
Unable to properly read Invalid configuration calibration file downloaded to controller.
the configuration portion Unsuccessful download of calibration file to controller.
01 - 05 Invalid Configuration of the calibration from Failed FLASH memory within controller.
memory
Unable to properly read Invalid configuration calibration file downloaded to controller.

the application portion Unsuccessful download of calibration file to controller.
01 - 06 Invalid Application of the calibration from Failed FLASH memory within controller.
memory
Diagnostic data not Power interruption during saving of data to non-volatile memory.
Internal Corrupted Diagnostic properly saved to NVM Failed FLASH memory within controller.
01 - 08
Data and has been reset
Warranty data not Power interruption during saving of data to non-volatile memory.
properly saved to NVM Failed FLASH memory within controller.
01 - 09 Corrupted Warranty Data
and has been reset
History data not Power interruption during saving of data to non-volatile memory.
properly saved to NVM Failed FLASH memory within controller.
01 - 10 Corrupted History Data
and has been reset
EMP Engineering Special Engineering Hardware/Software diagnostic codes triggered by malfunctions within TMC
TMC Hardware
01 - nn Test/Diagnostic Codes hardware/software. If any codes other than those listed above are observed, call EMP Technical
Diagnotics Codes
Services.
Voltage High Voltage regulator set incorrectly.

02 - 01 Over-Voltage Voltage regulator failure.
Alternator failure.
Voltage Low Alternator failure.
Electrical loads too high.
02 - 02 Under-Voltage
Voltage Corroded wiring or poor connections in wakeup line.
Corroded wiring in 24V power line.
Unexpected loss of igniti Failed wakeup wiring/connector/fuse to fan.
Failed internal circuitry of fan.
02 - 03 Ignition
Incorrect software/calibration installed.
Electrical Current leakage path internal to connector due to contamination.
The system controller is Failed wakeup wiring/connector/fuse to specified fan.

not receiving feedback Failed power wiring/connector/fuse to specified fan.
from this controller on Failed ground wiring/connector to specified fan.
Component the CAN bus. Failed EMP-Link wiring/connector to specified fan.
03 - NN Controller #NN
Communication Failed internal circuitry of fan.
Incorrect fan software/calibration installed.
Incorrect/failed Address resistor.
Electrical Current leakage path internal to connector due to contamination.
Internal temperature Excessively hot environmental conditions.

Component reported by component Failed internal temperature sensor.
04 - NN Controller #NN
Overtemperature is too high.
The motor speed Over/undervoltage outside of operational level.

feedback from the Motor (such as fan blades) obstructed (snow/ice/debris).
component controller is Failed motor.
Motor Inoperable 05 - NN Controller/Motor #NN
zero when the motor is Failed internal driver circuitry in fan.
commanded on. Incorrect component controller software/calibration installed.
The motor speed Low voltage to component.

feedback from the Excessive restriction of air flow.
component controller is Excessive friction on motor (such as fan blades or bearings).
Motor Speed Low 06 - NN Controller/Motor #NN lower than the Corroded wiring or poor connections on power wiring to fan.
commanded RPM. Weak motor.
Incorrect fan software/calibration installed.
Wrong fan or fan motor installed.
measured input is Plugged heat exchanger/restricted air flow.

Engine Coolant beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 01
Temperature values Fan failures (should be indicated by additional fault codes).
Required heat rejection higher than system capacity to cool.
reported (J1939) input Plugged heat exchanger/restricted air flow.
Engine Coolant is beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 02
Charge Air Cooler is beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 03
Charge Air Cooler beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 04
Control
Engine Compartment beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 05
Transmission Oil beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 06
Transmission Oil is beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 07
is beyond expected Inadequate electrical supply (should be indicated by additional fault codes).
07 - 08 Retarder Temperature
values Fan failures (should be indicated by additional fault codes).

______________ Diagnostic Codes Diagnostic Codes
Fault Type Fault Code Source / Description Explanation: Potential Cause(s):
open circuit detected Failed wiring/connector between TMC and sensor

08 - 02 Sensor #1 Open Circuit Failed sensor
Failed TMC circuitry.
short circuit between Failed wiring/connector between TMC and sensor
08 - 03 Sensor #1 Short Circuit sensor hi/lo or sensor hi Failed sensor
shorted to ground Failed TMC circuitry.
Sensor
The system controller is Failed wiring/connector between TMC and vehicle CAN.
J1939 EEC1 - Engine not receiving feedback Failed TMC circuitry.
09 - 01
Speed from the engine Sending device failed or not connected to J1939 Data Link
controller on the CAN
The system controller is Sending device does not support this parameter or message.
J1939 ET1 - Engine not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 02
Coolant Temperature expected data on the Failed TMC circuitry.
CAN bus. Sending device failed or not connected to J1939 Data Link.
J1939 IC1 - Intake not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 03
Manifold Temperature expected data on the Failed TMC circuitry.
J1939 CM1 - Requested
not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 04 Percent Fan Speed from
expected data on the Failed TMC circuitry.
Transmission
J1939 TRF1 -
Vehicle not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 05 Transmission Oil
Communication expected data on the Failed TMC circuitry.
Temperature
J1939 RF - Hydraulic not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 06
Retarder Oil Temperature expected data on the Failed TMC circuitry.
J1939 CCVS - Wheel not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 07
Based Vehicle Speed expected data on the Failed TMC circuitry.
J1939 EEC2 - Engine
not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 08 Percent Load At Current
expected data on the Failed TMC circuitry.
Speed
J1939 ET1 - Engine Oil not receiving the Failed wiring/connector between TMC and vehicle CAN.
09 - 09
Temperature expected data on the Failed TMC circuitry.

Troubleshoot Fault Code 01-08

Description High internal temperature of TMC
Fault Detection:
When the reported internal temperature of the TMC is
greater than 130 degC for 15 seconds
Fault Clearing:
When the reported internal temperature of the TMC is
less than 125 degC for 2 seconds
Possible Causes  Hot environmental conditions
 Failed internal circuitry of TMC
Possible Effects  Fans running at default speed
References
Troubleshooting Procedures:
Diagnostic Procedures:  Check Controller Environmental Conditions
Referenced By:


Description Invalid configuration calibration within the TMC
Fault Detection:
When the configuration calibration is invalid within
memory
Fault Clearing:
When the configuration calibration is valid within
memory
Possible Causes  Invalid configuration calibration downloaded to controller
 Unsuccessful download of configuration calibration to
controller
 Failed internal memory of TMC
References
Diagnostic Procedures:
Referenced By:
Troubleshoot
Fault Code
01-05
Download TMC
Calibration
Is Problem
Replace
Resolved No
TMC
?
Yes
Done


Description Invalid application calibration within the TMC
Fault Detection:
When the application calibration is invalid within memory
Fault Clearing:
When the application calibration is valid within memory
Possible Causes  Invalid application calibration downloaded to controller
 Unsuccessful download of application calibration to
controller
 Failed internal memory of TMC
References
Referenced By:
Troubleshoot
Fault Code
01-06
Download
TMC
Calibration
Is Problem
Replace
Resolved No
TMC
?
Yes
Done


Description Corrupted Diagnostic Data within TMC
Fault Detection:
When the diagnostic data is invalid within memory and
has been reset
Fault Clearing:
When the diagnostic data is successfully saved to
memory
Possible Causes  Power interruption during saving of data to non-volatile
memory
 Failed internal FLASH memory within TMC
Possible Effects  Lost diagnostic data
References
Referenced By:
Troubleshoot
Fault Code
01-08
Create A Diagnostic Fault
Cycle Ignition Off Then

Back On To See If Fault Is
Successfully Saved
Is Problem
Replace
Resolved No
TMC
?
Yes
Done

Description Corrupted Warranty Data within TMC
Fault Detection:
When the warranty data is invalid within memory and
has been reset
Fault Clearing:
When the warranty data is successfully saved to
memory
memory
Possible Effects  Lost warranty data
References
Referenced By:
Troubleshoot
Fault Code
01-09
Create A Diagnostic Fault

Back On To See If Fault Is
Successfully Saved
Is Problem
Replace
Resolved No
TMC
?
Yes
Done

Description Corrupted History Data within TMC
Fault Detection:
When the history data is invalid within memory and
has been reset
Fault Clearing:
When the history data is successfully saved to memory
memory
Possible Effects  Lost warranty data
References
Referenced By:
Troubleshoot
Fault Code
01-10
Run Kit Fans Manually

Back On To See If History
Is Successfully Saved
Is Problem
Replace
Resolved No
TMC
?
Yes
Done

Troubleshoot Fault Code 01-NN
Description Unexplained hardware/software error within TMC
Fault Detection:
When an unexpected hardware/software event is
detected within TMC operation
Fault Clearing:
When the event becomes inactive
Possible Causes  Software error
 Failed internal hardware or memory within TMC
Possible Effects  Incorrect system operation
References
Troubleshooting Procedures:  Call EMP if unexpected fault is detected
Referenced By:

Description Over-Voltage
Fault Detection:
When measured voltage is greater than 30.5 Volts for
10 seconds
Fault Clearing:
When measured voltage is less than 30.0 Volts for 2
seconds
Possible Causes  Sporadic high voltage transient provided to system
 High voltage provided to system
Possible Effects  Fan controllers disable fan operation or shut down
References
Troubleshooting Procedures:  Troubleshoot High Voltage
Diagnostic Procedures:  Check TMC Power Voltage
Referenced By:

Description Under-Voltage
Fault Detection:
When measured voltage is less than 24.0 Volts for 10
seconds
Fault Clearing:
When measured voltage is greater than 24.5 Volts for 2
seconds
Possible Causes  Sporadic low voltage transient provided to system
 Low voltage provided to system
 Failed system wakeup connector
 Incorrect voltage provided to system wakeup connector
 Failed TMC power connector
 Failed main wiring harness
Possible Effects  Fans unable to reach maximum speed
 Charge margin de-rate of fan speed commands
 Fan controllers disable fan operation or shut down
References
Troubleshooting Procedures:  Troubleshoot Low Voltage
 Troubleshoot System Wakeup
Diagnostic Procedures:  Check Battery Voltage
 Check TMC Power Voltage
1
 Inspect TMC Power Pins

 Check System Wakeup Voltage
Referenced By:

Troubleshoot
Fault Code
02-02
Check Fault Status No Clear Fault

Information Concern Code
Possible
Issue
Check Fail Troubleshoot

Battery Voltage Low Low Voltage
Pass
Repair
Check TMC Power Inspect TMC Power
Fail Fail TMC Power
Voltage Pins
Pins
Pass Pass
Replace Replace
TMC Main Harness

Description Loss of Wakeup Voltage
Fault Detection:
When the wakeup input is removed while the engine is
running for 15 seconds
Fault Clearing:
When the wakeup input is restored for 5 seconds
Possible Causes  Failed system wakeup connector
 Incorrect voltage provided to system wakeup connector
 Failed TMC power connector
 Failed TMC controller
Possible Effects  Cooling system not functional
References
Troubleshooting Procedures:  Troubleshoot System Wakeup
Diagnostic Procedures:  Inspect System Wakeup Connector
 Inspect TMC Wake Up Pin
 Check TMC Wakeup Voltage
Referenced By:



Description Failed Communication with Fan #NN
Fault Detection:
When the proprietary EMP-link status message from an
expected FiL-11 Fan is not received for 20 seconds
Fault Clearing:
When a single proprietary EMP-link status message
from the corresponding FiL-11 Fan is received.
Possible Causes  Failed TMC Communication
 Failed FiL-11 Fan Connector
 Failed FiL-11 Fan Communications
 Failed FiL-11 Fan Power
 Failed FiL-11 Fan Wakeup
Possible Effects  Fan runs at default speed
 Fan not operating
References
Troubleshooting Procedures:  Troubleshoot FiL-11 Fan Communication
 Troubleshoot FiL-11 Fan Power
 Troubleshoot FiL-11 Fan Wakeup
 Troubleshoot Fault Code 04-NN
Diagnostic Procedures:  Inspect FiL-11 EMP-Link Communication Pins
2
 Check FiL-11 Fan Operation

 Check FiL-11 Fan Power Voltage
 Check System Fuses
 Inspect Fuse Holder
Referenced By:  Troubleshoot Fan Slow Or Not Operating
 Troubleshoot Fan Running At High Speed
 Troubleshoot Fan Runs When Engine Off
 Troubleshoot JW Fans Running At High Speed
 Troubleshoot CAC Fans Running At High Speed
 Troubleshoot Service Tool Communications

Troubleshoot
Fault Code
03-NN
Are
All Fault Troubleshoot
Codes 03-NN Yes TMC EMP-Link #1
Active Communication
?
No
Is
Troubleshoot
Fault Code
Yes Fault Code
04-NN Active
04-NN
?
No
Inspect Repair FiL-11

Fail
FiL-11 Fan Power Pins Power Pins
Pass
Inspect
Repair FiL-11
FiL-11 Fan EMP-Link Fail
EMP-Link Pins
Pins
Pass
Troubleshoot
Check
Pass FiL-11 Fan
FiL-11 Fan Operation
Communication
Fail
Check
Troubleshoot
FiL-11 Fan Power Fail
FiL-11 Fan Power
Voltage
Pass
Troubleshoot
FiL-11 Fan Wakeup


Description Over-temperature of Controller #NN
Fault Detection:
When the reported internal temperature of a fan
controller is greater than 130 degC for 15 seconds.
Fault Clearing:
When the reported internal temperature of a fan
controller is less than 125 degC for 2 seconds.
Possible Causes  FiL-11 Fan located in high temperature area
 Failed internal circuitry of FiL-11 Fan
Possible Effects  Fan operating at reduced speed
 FiL-11 Fan not communicating
References
Diagnostic Procedures:  Check FiL-11 Fan Environmental Conditions
Referenced By:  Troubleshoot Fault Code 03-NN
 Troubleshoot Fan Slow Or Not Operating
Troubleshoot
Fault Code
04-NN
Check Controller Correct Controller

Environmental Fail Environmental
Conditions Conditions
Pass
Replace
FiL-11 Fan


Description Motor Not Operating
Fault Detection:
When the reported motor speed is less than 675 RPM for
20 seconds.
Detection will not occur if any of the following apply:
 the motor is commanded off
 reported motor speed is unavailable
 voltage is greater than 30.5V
 voltage is less than 24.0V
Fault Clearing:
When the reported motor speed is greater than 675
RPM for 5 seconds.
Clearing will not occur if any of the following apply:
 the motor is commanded off
 reported motor speed is unavailable
Possible Causes  Sporadic electrical transient provided to system
 High controller temperature
 Degraded fan performance
 Fan obstruction
 Air flow obstruction
 Failed FiL-11 fan connector
 Incorrect voltage provided to system
 Failed fan
Possible Effects  Excessive fan speeds on operating fans
 High engine coolant temperatures
 High engine intake air temperatures
 Engine de-rate or shutdown
Fault Tree Assumptions  Fault code is active
References
Troubleshooting Procedures:  Troubleshoot Fan Slow Or Not Operating
Referenced By:


Description Motor Speed Low
Fault Detection:
When the reported fan motor speed is less than 75% of
the commanded fan motor speed for 20 seconds.
 the fan motor is commanded off
 the fan motor is unable to successfully start
 reported fan motor speed is unavailable
Fault Clearing:
When the reported fan motor speed is greater than 75%
of the commanded fan motor speed for 5 seconds.
 the fan motor is commanded off
 the fan motor is unable to successfully start
 reported fan motor speed is unavailable
 High controller temperature
 Fan obstruction
 Failed fan
Possible Effects  Excessive fan speeds on operating fans
References
Referenced By:

Troubleshoot
Fault Code
06-NN
Troubleshoot
Fan Slow Or Not
Operating


Description Measured Coolant Temperature High
Fault Detection:
When the measured coolant temperature exceeds a
calibration temperature rise above the maximum
setpoint temperature for 15 seconds.
 The temperature used for fan control is invalid
 Within 30 seconds of engine start
Fault Clearing:
When the measured coolant temperature falls 5 degC
below the fault detection temperature
Possible Causes  Airflow obstruction
 Incorrect coolant level
 Incorrect coolant mixture
 Air entrapment within coolant
 Damaged fans
 Improper hot air recirculation prevention
 Dirty/plugged heat exchanger
 Low fan performance
 Failed engine thermostat
 Failed coolant sensor connection
 Failed coolant sensor
 Failed TMC sensor connector
 Failed internal circuitry in TMC
 Incorrect coolant temperature measurement
Possible Effects  Engine de-rate or shutdown
References
Troubleshooting Procedures:  Troubleshoot High Coolant Temperature
Referenced By:



Description Reported J1939 Coolant Temperature High
Fault Detection:
When the reported J1939 coolant temperature exceeds
a calibration temperature rise above the maximum
Fault Clearing:
When the reported coolant temperature falls 5 degC
 Damaged fans
 Failed Engine ECU coolant sensor
References
Referenced By:



Description Reported Charge Air Cooler Temperature High
Fault Detection:
When the reported J1939 charge air cooler temperature
exceeds a calibration temperature rise above the
maximum setpoint temperature for 15 seconds.
Fault Clearing:
When the reported charge air cooler temperature falls
7.5 degC below the fault detection temperature
 Intake air plumbing leaks
 Damaged fans
 Failed Engine ECU charge air sensor
 Incorrect CAC temperature measurement
References
Troubleshooting Procedures:  Troubleshoot High Intake Air Temperature
Referenced By:



Description Measured Charge Air Cooler Temperature High
Fault Detection:
When the measured charge air cooler temperature
Fault Clearing:
When the measured charge air cooler temperature falls
 Damaged fans
 Failed charge air sensor connector
 Failed charge air sensor
References
Troubleshooting Procedures:  Troubleshoot High Intake Air Temperature
Referenced By:



Description Engine Compartment Temperature High
Fault Detection:
When the measured engine compartment temperature
Fault Clearing:
When the measured engine compartment temperature
falls 7.5 degC below the fault detection temperature
 Improper engine compartment venting
 Damaged fans
 Failed engine compartment air sensor connector
 Failed engine compartment air sensor
 Failed engine compartment temperature sensor harness
Possible Effects  Overheat of engine compartment
References
Troubleshooting Procedures:  Troubleshoot High Engine Compartment Temperature
Referenced By:



Description Measured Transmission Oil Temperature High
Fault Detection:
When the measured transmission oil temperature
Fault Clearing:
When the measured transmission oil temperature falls
 Damaged fans
 Failed transmission oil sensor harness
 Failed transmission oil sensor
 Failed transmission oil sensor connector
References
Troubleshooting Procedures:  Troubleshoot High Transmission Oil Temperature
Referenced By:



Description Reported Transmission Oil Temperature High
Fault Detection:
When the reported J1939 transmission oil temperature
Fault Clearing:
When the measured transmission oil temperature falls
 Damaged fans
 Failed transmission oil sensor harness
 Failed transmission oil sensor
References
Troubleshooting Procedures:  Troubleshoot High Transmission Oil Temperature
Referenced By:


Description Reported Retarder Temperature High
Fault Detection:
When the reported retarder temperature exceeds a
calibration temperature rise above the maximum
Fault Clearing:
When the reported retarder temperature falls 7.5 degC
 Damaged fans
 Failed retarder sensor harness
 Failed retarder sensor
References
Troubleshooting Procedures:  Troubleshoot High Retarder Temperature
Referenced By:

Description Coolant Temperature Sensor (Sensor #1) Open Circuit
Fault Detection:
When the measured resistance is greater than 135
kOhms for 5 seconds after a prior determination that
ambient conditions are above (-10 degC) via either this
sensor or a component controller reported internal
temperature.
 the system is calibrated to control to the coolant
temperature reported by the engine on the J1939
data link
Fault Clearing:
When the measured resistance is less than 54 kOhms
for 2 seconds
Possible Causes  Failed TMC Sensor Connector
 Failed Coolant Sensor Connector
 Failed Coolant Temperature Sensor
 Failed Main Wiring Harness
Possible Effects  Fans associated with coolant temperature regulation
running at default speed
References
Troubleshooting Procedures:  Troubleshoot Coolant Sensor Measurement
Referenced By:  Troubleshoot Fan Running At High Speed


Description Coolant Temperature Sensor (Sensor #1) Short Circuit
Fault Detection:
When the measured resistance is less than 58 Ohms for
5 seconds.
 the system is calibrated to control to the coolant
temperature reported by the engine on the J1939
data link
Fault Clearing:
Ohms for 2 seconds
 Failed Coolant Sensor Connector
 Failed Coolant Temperature Sensor
References
Troubleshooting Procedures:  Troubleshoot Coolant Sensor Measurement
Troubleshoot
Fault Code
08-03
Troubleshoot
Coolant Sensor
Measurement


Description Charge Air Temperature Sensor (Sensor #2) Open Circuit
Fault Detection:
kOhms for 5 seconds.
 the system is calibrated to control to the intake
manifold temperature reported by the engine on
the J1939 data link
Fault Clearing:
for 2 seconds
 Failed Charge Air Sensor Connector
 Failed Charge Air Temperature Sensor
Possible Effects  Fans associated with charge air temperature regulation
References
Troubleshooting Procedures:  Troubleshoot Charge Air Sensor Measurement


Description Charge Air Temperature Sensor (Sensor #2) Short Circuit
Fault Detection:
5 seconds.
the J1939 data link
Fault Clearing:
When the measured resistance is greater than 77 Ohms
for 2 seconds
References
Troubleshooting Procedures:  Troubleshoot Charge Air Sensor Measurement


Description External Temperature Sensor (Sensor #3) Open Circuit
Fault Detection:
 There is not external temperature sensor installed
(Engine compartment or Transmission
temperature)
Fault Clearing:
for 2 seconds
 Failed External Temperature Sensor Connector
 Failed External Temperature Sensor
Possible Effects  Fans associated with external temperature regulation
References
Troubleshooting Procedures:  Troubleshoot External Temperature Sensor
Measurement


Description External Temperature Sensor (Sensor #3) Short Circuit
Fault Detection:
5 seconds.
 There is not external temperature sensor installed
(Engine compartment or Transmission
temperature)
Fault Clearing:
When the measured resistance is greater than 77 Ohms
for 2 seconds
 Failed External Temperature Sensor Connector
 Failed External Temperature Sensor
Possible Effects  Fans associated with external temperature regulation
References
Troubleshooting Procedures:  Troubleshoot External Temperature Sensor
Measurement


Description Engine Communication
Fault Detection:
When the J1939 EEC1 message from the engine
containing engine speed has not been received for 15
seconds.
 the system is not calibrated to require engine
communications AND the EEC1 message has
not been detected previously
Fault Clearing:
A single J1939 EEC1 message from the engine
containing engine speed is received
Possible Causes  Failed J1939 connection to the engine
Possible Effects  Loss of thermal soak inhibit control logic
 Loss of EMPower Connect service tool communication
References
Troubleshooting Procedures:  Troubleshoot Vehicle J1939 Connection
Diagnostic Procedures:  Check Engine Communication
 Check TMC J1939 Communication
Referenced By:  Troubleshoot CAC Fans Run At High Speed
 Troubleshoot JW Fans Run At High Speed
Troubleshoot
Fault Code
09-01
Check
Fail
Engine Communication
Pass
Check
Troubleshoot Vehicle
TMC J1939 Fail
J1939 Connection
Communication
Pass
Contact EMP
Support


Description Failed J1939 Engine Coolant Temperature
Fault Detection:
When the J1939 reported engine coolant temperature
contained within the ET1 message has not been
received for 10 seconds.
 the system is not calibrated to control fan speed
based upon J1939 reported engine coolant
temperature
Fault Clearing:
A single J1939 reported engine coolant temperature is
received
Possible Effects  Fans associated with engine coolant temperature
regulation running at default speed
References
Referenced By:  Troubleshoot JW Fans Running At High Speed
Troubleshoot
Fault Code
09-02
Check
Fail
Pass
Check
TMC J1939 Fail
J1939 Connection
Communication
Pass
Contact EMP
Support


Description Failed J1939 Intake Manifold Temperature
Fault Detection:
When the J1939 reported engine intake manifold
temperature contained within the IC1 message has not
been received for 10 seconds.
based upon J1939 reported engine intake
manifold temperature
Fault Clearing:
A single J1939 reported engine intake manifold temperature is
received
Possible Effects  Fans associated with engine intake manifold
temperature regulation running at default speed
References
Referenced By:  Troubleshoot CAC Fans Running At High Speed
Troubleshoot
Fault Code
09-03
Check
Fail
Pass
Check
TMC J1939 Fail
J1939 Connection
Communication
Pass
Contact EMP
Support


Description Invalid/Unavailable J1939 Transmission Fan Request
Fault Detection:
When the J1939 transmission fan request contained
within the CM1 message has not been received for 10
seconds.
based upon J1939 transmission fan request
Fault Clearing:
A single J1939 transmission fan request is received
Possible Causes  Failed J1939 connection to the transmission
regulation not responding to transmission cooling needs
 Transmission over-temperature
References
Diagnostic Procedures:  Check Transmission Communication
Troubleshoot
Fault Code
09-04
Check
Transmission Fail
Communication
Pass
Check
TMC J1939 Fail
J1939 Connection
Communication
Pass
Contact EMP
Support


Description Invalid/Unavailable J1939 Transmission Sump Temperature
Fault Detection:
When the J1939 message containing the transmission
sump temperature (TRF1) has not been received for 10
seconds.
based upon J1939 transmission sump
temperature
Fault Clearing:
A single J1939 message containing transmission sump
temperature is received
References
Troubleshoot
Fault Code
09-05
Check
Transmission Fail
Communication
Pass
Check
TMC J1939 Fail
J1939 Connection
Communication
Pass
Contact EMP
Support


Description Invalid/Unavailable J1939 Retarder Temperature
Fault Detection:
When the J1939 message containing the retarder
temperature (RF) has not been received for 10 seconds.
based upon J1939 retarder temperature
Fault Clearing:
A single J1939 message containing retarder
temperature is received
References
Troubleshoot
Fault Code
09-06
Check
Transmission Fail
Communication
Pass
Check
TMC J1939 Fail
J1939 Connection
Communication
Pass
Contact EMP
Support


Description Invalid/Unavailable J1939 Vehicle Wheel Speed
Fault Detection:
When the J1939 CCVS Vehicle Wheel Speed message
has not been received for 10 seconds. Detection will
not occur if any of the following apply:
 the system is not connected to the J1939 bus or
curbside quiet mode is disabled
Fault Clearing:
A single J1939 message containing vehicle wheel speed
is received
Possible Causes  Failed J1939 connection to the vehicle
 Sending device is not connected to J1939 bus
Possible Effects  Curbside quiet mode not functional
 Thermal soak function not functional
References
Diagnostic Procedures:  Check TMC J1939 Communication
Referenced By:

Description Failed J1939 Engine Percent Load
Fault Detection:
When the J1939 reported engine percent load contained
within the EEC2 message has not been received for 10
seconds.
based upon J1939 reported engine percent load
Fault Clearing:
A single J1939 reported engine percent load is received
Possible Effects
References
Referenced By:


Description Failed J1939 Engine Oil Temperature
Fault Detection:
When the J1939 reported engine oil temperature
contained within the ET1 message has not been
received for 10 seconds.
based upon J1939 reported engine oil
temperature
Fault Clearing:
A single J1939 reported engine oil temperature is
received
Possible Effects
References
Referenced By:

Troubleshoot System Wakeup

Description Failed wakeup signal to cooling system
Possible Causes  High voltage provided to system
 Failed system ground connection
 Failed system wakeup voltage
 Failed fuse on wakeup enable input
 Failed vehicle wakeup wiring
Possible Effects  System does not function
References
 Troubleshoot Low Voltage
Diagnostic Procedures:  Check System Wakeup Voltage
 Check Battery Voltage
 Inspect System Wakeup Connector
 Check System Ground Continuity
 Check Vehicle Wakeup Source Voltage
Referenced By  Troubleshoot Fault Code 02-02
 Troubleshoot Fault Code 02-03
 Troubleshoot TMC Wakeup
 Troubleshoot Fan Runs When Ignition Off
 Troubleshoot System Not Functioning

Troubleshoot
System Wakeup
Check
Fail Fail Troubleshoot
System Wakeup
Low High High Voltage
Voltage
Fail
Zero
Inspect Repair System

Check
Pass System Wakeup Fail Wakeup
Battery Voltage
Connector Connector
Fail Low Pass
Check Repair
Troubleshoot
System Ground Fail System Ground
Low Voltage
Continuity Connection
Pass
Check Repair Vehicle

Vehicle Wakeup Source Fail Wakeup
Voltage Voltage
Pass
Repair Vehicle
Wakeup Wiring

Troubleshoot System Power
Description Failed electrical power to cooling system
 Failed lug connection
 Failed system ground connection
 Failed system fuse
 Failed system power connection
Possible Effects  System does not function
References
Diagnostic Procedures:  Check System Voltage
 Inspect Lug Connections
 Check System Ground Continuity
 Check System Fuse
Referenced By  Troubleshoot System Not Functioning

Troubleshoot
System Power
Fail Check Fail Troubleshoot

Low System Voltage High High Voltage
Fail
Zero
Check Inspect Repair Lug

Pass Fail
Battery Voltage Lug Connections Connections
Fail Low Pass
Check Repair
Troubleshoot
System Ground Fail System Ground
Low Voltage
Continuity Wiring
Pass
Check Replace
Fail
System Fuse System Fuse
Pass
Repair System
Power Wiring

Troubleshoot TMC Wakeup
Description Failed wakeup to TMC controller
Possible Causes  Incorrect voltage provided to system wakeup
 Failed TMC Grey 12 pin Deutsch connector
Possible Effects  Fans run at default speed
 Lack of diagnostic LED
 Lack of reverse functionality
 Unable to use EMPower Connect service tool
References
Diagnostic Procedures:  Inspect TMC Grey 12 Pin Connector
Referenced By  Troubleshoot TMC Not Functioning

Troubleshoot
TMC Wakeup
Inspect Repair TMC

TMC Grey 12 Pin Fail Grey 12 Pin
Connector Connector
Pass
Troubleshoot Fail Check Replace

Pass
High Voltage High TMC Wakeup Voltage TMC
Fail Low
Or
Fail Zero
Check
Troubleshoot
System Wakeup Fail
System Wakeup
Voltage
Pass

System Wakeup Fail Wakeup
Connector Connector
Pass
Replace Main
Harness

Troubleshoot FiL-11 Fan Wakeup
Troubleshoot FiL-11 Fan Wakeup

Description Failed wakeup to FiL-11 Fan
Possible Causes  Incorrect voltage provided to system wakeup
 Failed FiL-11 fan power connector
 Failed FiL-11 Fan
Possible Effects  Fan runs at default speed
References
Diagnostic Procedures:  Inspect FiL-11 Fan Power Pins
 Check FiL-11 Fan Wakeup Voltage
Referenced By  Troubleshoot Fault Code 03-NN
Troubleshoot
FiL-11 Fan Wakeup
Repair FiL-11
Inspect
Fail Fan Power
FiL-11 Fan Power Pins
Pins
Pass
Check
Troubleshoot Fail Replace
FiL-11 Fan Wakeup Pass
High Voltage High FiL-11 Fan
Voltage
Fail Low
Or
Fail Zero
Check
Troubleshoot
System Wakeup Fail
System Wakeup
Voltage
Pass

System Wakeup Fail Wakeup
Connector Connector
Pass
Replace Main
Harness

Troubleshoot FiL-11 Fan Communications
Troubleshoot FiL-11 Fan Communication
Description Communication with FiL-11 Fan
Possible Causes  Failed FiL-11 connector
 Failed FiL-11 controller
 Failed address resistor connection
 Failed address resistor
Possible Effects  Fault Code 03-NN
 Fan running at default speed
 Fan running at incorrect speed
References
Diagnostic Procedures:  Inspect FiL-11 Fan Communications Pins
 Check FiL-11 Fan Address Resistance
 Check FiL-11 Fan EMP-Link Continuity
 Inspect Address Resistor Connector

 Troubleshoot A Fan Running At High Speed
 Troubleshoot TMC Not Functioning

Troubleshoot FiL-11 Fan Communications
Troubleshoot
FiL-11 Fan
Communication
Repair
Inspect
Fail FiL-11 Fan
FiL-11 Fan Connector
Connector
Pass
Check Repair Address

Inspect Address
FiL-11 Fan Address Fail Fail Resistor
Resistor Connector
Resistance Connector
Pass Pass
Check Replace
Replace Main Check
Fail FiL-11 Fan EMP-link Fail Address
Kit Harness Address Resistor
Continuity Resistor
Pass Pass
Replace Replace Main

FiL-11 Fan Kit Harness

Troubleshoot TMC Power
Description Loss of power to TMC controller
 Failed lug connections
 Failed fuse
 Failed fuse holder
 Failed main harness
 Failed Grey 12 pin connector
 Fans not operational
 Fans running always at default speed
 Over-temperature conditions
 Engine de-rate
References
Diagnostic Procedures:  Check TMC Power Voltage
 Check System Voltage
 Check Controller Fuse
Referenced By  Troubleshoot TMC Not Functioning


Troubleshoot FiL-11 Power
Troubleshoot FiL-11 Fan Power

Description Loss of power to FiL-11 Fan
 Failed lug connections
 Failed fuse
 Failed fuse holder
 Fan not operational
 Over-temperature conditions
 Engine de-rate
References
Diagnostic Procedures:  Check FiL-11 Power Voltage
 Check Fan Fuse

Troubleshoot FiL-11 Power

Troubleshoot High Voltage

Description High voltage at EMP inputs
Possible Causes  Voltage regulator setting incorrect
 Failed voltage regulator
Possible Effects  Fan controllers disable fan operation or shut down
References
Diagnostic Procedures:  Check Battery Voltage
 Troubleshoot System Power
 Troubleshoot TMC Power

Troubleshoot
High Voltage
Adjust Voltage
Regulator
Check
Pass Done
Battery Voltage
Fail High
Replace
Voltage
Regulator
Check
Pass Done
Battery Voltage
Fail High
Is
the Alternator Contact
An EMP No Vehicle
Product Support
?
Yes
Contact EMP
Support

Troubleshoot Low Voltage
Description Low voltage at EMP inputs
Possible Causes  Failed charging system connections
 Voltage regulator setting incorrect
 Failed voltage regulator
 Failed alternator
Possible Effects  Disable fan operation or shut down
 Over temperature conditions
 Engine derate
References
Diagnostic Procedures:  Inspect Charging System Connections

Troubleshoot
Low Voltage
Inspect Repair Charging

Charging System Fail System
Connections Connections
Pass
Adjust Voltage
Regulator
Check
Pass Done
Battery Voltage
Fail Low
Replace
Voltage
Regulator
Check
Pass Done
Battery Voltage
Fail Low
Replace
Alternator

Troubleshoot Vehicle J1939 Connection
Description Failed reception of J1939 messages from the vehicle
Possible Causes  Failed system J1939 connector
 Failed J1939 interface harness
 Failed J1939 vehicle wiring
 Failed J1939 termination resistor
Possible Effects  Loss of curbside noise abatement feature
 Loss of thermal soak inhibit feature
 Loss of J1939 fan reversal feature
 Fans run at default speed if controlling to J1939
temperatures
 Unable to use EMPower Connect service tool
References
Diagnostic Procedures:  Inspect System J1939 Connector
 Check Vehicle J1939 Continuity
 Check TMC J1939 Continuity

 Troubleshoot Low Coolant Temperature
 Troubleshoot Service Tool Communication

J1939 Connection

System J1939 Fail J1939
Connector Connector
Pass
Check Check Replace

Vehicle J1939 Fail J1939 Interface Harness Fail J1939 Interface
Continuity Continuity Harness
Pass
Repair
Pass Vehicle J1939
Wiring
Replace J1939
Check J1939
Fail Termination
Termination Resistors
Resistor
Pass
Replace
Main Harness

Troubleshoot High Coolant Temperature
Description High Coolant Temperature
 Damaged fans
Possible Effects  Fault Code 07-01
References
 Troubleshoot Incorrect Coolant Temperature
Diagnostic Procedures:  Inspect Air Flow Path For Obstructions
 Check Coolant Level
 Check Coolant Mixture
 Check Cooling System Deaeration
 Inspect Fans
 Inspect Recirculation Prevention
 Inspect Heat Exchanger for Cleanliness
 Test Maximum Fan Performance
 Test Thermostat Operation
 Perform Test Drive
 Determine Coolant Sensor Used
 Compare Coolant Measurements
 Troubleshoot High Transmission Temperature

Troubleshoot
High Coolant
Temperature
Are Inspect
Troubleshoot Clean Heat
Fault Codes Other Heat Exchanger For Fail
Yes Other Fault Exchanger
Than 07-NN Present Cleanliness
Codes
?
Pass
No
Remove
Inspect Air Flow Path
Fail Airflow Test Troubleshoot
For Obstructions
Obstructions Maximum Fan Fail Fan Slow Or Not
Performance Operating
Pass
Pass
Adjust Coolant
Check Coolant Level Fail Test
Level Replace
Thermostat Fail
Thermostat
Operation
Pass
Pass
Perform Test
Pass Done
Check Adjust Coolant Drive
Fail
Coolant Mixture Misture
Fail
Pass
Pass
Determine Coolant
Sensor Used
Deaerate
Check Cooling System Cooling
Fail Cooling
Deaerated System
System
Sensor
Pass
Troubleshoot
Pass Engine Compare
Fail Incorrect Coolant
Sensor Coolant Measurements
Temperature
Inspect Fans Fail Replace Fan Pass
Pass Contact EMP

Pass Support
Inspect Correct
Recirculation Fail Recirculation
Prevention Prevention
Pass

Troubleshoot Low Coolant Temperature
Description Low Coolant Temperature
Possible Causes  Failed TMC EMP-Link communication
 Failed J1939 communications with vehicle
Possible Effects  Lack of cab heating
References
Troubleshooting Procedures:  Troubleshoot FiL-11 Fan Communication
 Troubleshoot Vehicle J1939 Connection
Diagnostic Procedures:  Test Thermostat Operation
 Determine Coolant Sensor Used
 Compare Coolant Measurements
 Verify J1939 Coolant Temperature Received
 Check Engine Communication
 Check FiL-11 EMP-Link Continuity
Referenced By

Troubleshoot
Low Coolant
Temperature
Check Troubleshoot
TMC EMP-Link Fail TMC EMP-Link
Communication Communication
Pass
Are Any Fault Troubleshoot

Codes Active Yes Fault Code
? XX-NN
No
Test Replace
Fail
Thermostat Operation Thermostat
Pass
Cooling Troubleshoot
Determine Coolant Compare
System Fail Incorrect Coolant
Sensor Used Coolant Measurements
Sensor Temperature
Engine
Pass
Sensor
Verify J1939 Coolant Contact EMP

Temperature Received Support
Fail
Check Troubleshoot Vehicle

Fail
Pass Engine Communication J1939 Connection
Pass
Contact EMP
Support

Troubleshoot Incorrect Coolant Temperature
Description Incorrect Coolant Temperature
Possible Causes  Failed TMC Black 12 pin connector
 Failed coolant sensor connector
 Failed engine sensor measurement
Possible Effects  High engine coolant temperature
 Low engine coolant temperature
 Lack of cab heating
References
Diagnostic Procedures:  Compare Coolant Measurements
 Inspect TMC Sensor Connector
 Inspect Coolant Sensor Connector
 Check Coolant Sensor Harness Continuity
 Test TMC Coolant Input Circuit
 Check Engine ECU Coolant Measurement
Referenced By  Troubleshoot High Coolant Temperature

Troubleshoot
Incorrect Coolant
Temperature
Pass
Compare Coolant
Pass Done
Measurements
Fail
Repair TMC
Inspect TMC Black 12
Fail Black 12 Pin
Pin Connector
Connector
Pass
Repair Coolant
Inspect Coolant Sensor
Fail Sensor
Connector
Connector
Pass
Check Coolant Sensor Replace Main

Fail
Harness Continuity Harness
Pass
Test TMC Coolant Input Replace

Fail
Circuit TMC
Pass
Replace
Coolant Sensor
Compare Coolant
Pass Done
Measurements
Fail
Check Correct Engine

Engine ECU Coolant Fail ECU Coolant
Measurement Measurement
Pass
Contact EMP
Support

Troubleshoot Coolant Sensor Measurement

Description Failed coolant sensor measurement
Possible Causes  Failed TMC Black 12 pin connector
 Failed coolant sensor connector
References
Diagnostic Procedures:  Inspect TMC Sensor Connector
 Check Coolant Sensor Resistance
 Test TMC Coolant Input Circuit
Referenced By:  Troubleshoot Fault Code 08-02

Troubleshoot
Coolant Sensor
Measurement
Repair
Inspect
Fail TMC Sensor
TMC Sensor Connector
Connector
Pass
Inspect Repair
Coolant Sensor Fail Coolant Sensor
Connector Connector
Pass
Check
Replace
Coolant Sensor Fail
Coolant Sensor
Resistance
Pass
Check
Replace Main
Coolant Sensor Fail
Harness
Harness Continuity
Pass
Test
Replace
TMC Coolant Input Fail
TMC
Circuit
Pass
Contact EMP
Support

Troubleshoot High Intake Air Temperature
Description Engine Reports High Intake Air Temperature
 Damaged fans
 Failed intake air temperature measurement
References
 Troubleshoot Charge Air Sensor Measurement
Diagnostic Procedures:  Inspect Air Flow Path For Obstructions
 Inspect Intake Air For Leaks
 Inspect Fans
 Inspect Recirculation Prevention
 Inspect Heat Exchanger for Cleanliness
 Perform Test Drive
 Determine Intake Air Sensor Used

Troubleshoot
High Intake Air
Temperature
Are
Troubleshoot
Fault Codes Other Test Troubleshoot
Yes Other Fault
Than 07-NN Present Maximum Fan Fail Fan Slow Or Not
Codes Performance Operating
?
Pass
No
Remove
Inspect Air Flow Path
Fail Airflow
for Obstructions Perform
Obstructions Pass Done
Test Drive
Pass
Fail
Cooling Troubleshoot
Determine
Inspect Repair Intake System Charge Air Sensor
Fail Intake Air Sensor Used
Intake Air For Leaks Air Leaks Sensor Measurement
Pass Engine
Sensor
Contact EMP
Replace Support
Inspect Fans Fail
Fan
Pass
Pass
Inspect Correct
Recirculation Fail Recirculation
Prevention Prevention
Pass
Inspect
Clean Heat
Heat Exchanger For Fail
Exchanger
Cleanliness
Pass

Troubleshoot Charge Air Sensor Measurement

Description Charge Air Temperature Sensor (Sensor #2) Open Circuit
Fault Detection:
the J1939 data link
Fault Clearing:
for 2 seconds
Possible Causes  Failed TMC Black 12 Pin Connector
References
Diagnostic Procedures:  Inspect TMC Sensor Connector
 Inspect Charge Air Sensor Connector
 Check Charge Air Sensor Resistance
 Check Charge Air Sensor Harness Continuity
 Test TMC Charge Air Input Circuit
 Troubleshoot High Intake Air Temperature

Troubleshoot
Charge Air Sensor
Measurement
Inspect Repair
TMC Black 12 Pin Fail TMC Black 12
Connector Pin Connector
Pass
Inspect Repair Charge

Charge Air Sensor Fail Air Sensor
Connector Connector
Pass
Check Replace
Charge Air Sensor Fail Charge Air
Resistance Sensor
Pass
Check
Replace Main
Charge Air Sensor Fail
Harness
Harness Continuity
Pass
Test
Replace
TMC Charge Air Input Fail
TMC
Circuit
Pass
Contact EMP
Support

Troubleshoot High Transmission Temperature
Troubleshoot High Transmission Temperature
Description High Transmission Temperature
Possible Causes  High Coolant Temperature
 Incorrect Transmission Fluid Level
Possible Effects
References
Diagnostic Procedures:  Check Transmission Fluid Level
Referenced By  Troubleshoot JW Fans Running At High Speed
Troubleshoot
High Transmission
Temperature
Are
Fault Codes Troubleshoot
Yes
Present Fault Codes
?
No
Is
Troubleshoot
Coolant
Yes High Coolant
Temperature High
Temperature
?
No
Check Adjust
Transmission Fluid Fail Transmission
Level Fluid Level
Pass
Contact EMP
Support

Troubleshoot Fan Slow Or Not Operating

Description A fan is operating too slow or is not operating at all
 High FiL-11 Fan temperature
 Fan obstruction
 Failed fan
 Open FiL-11 fuse
 Fault Code 06-NN
 Excessive fan speeds on operating fans
References
Troubleshooting Procedures:  Troubleshoot Fault Code 03-NN
 Troubleshoot High Voltage
 Troubleshoot FiL-11 Power
Diagnostic Procedures:  Check Fan Operation
 Verify Fan Is Not Obstructed
 Inspect FiL-11 Power Pins
 Check FiL-11 Power Voltage
 Check FiL-11 Wake Up Voltage
Referenced By:  Troubleshoot Fault Code 05-NN
 Troubleshoot High Coolant Temperature


Troubleshoot A Fan Running At High Speed
Troubleshoot A Fan Running At High Speed
Description A fan is always running at high speed
Possible Causes  Loss of EMP-Link communication
 Low engine coolant temperatures
 Low engine intake air temperatures
References
 Troubleshoot FiL-11 Fan Communication
Diagnostic Procedures:  Check FiL-11 EMP-Link Continuity
Referenced By:
Troubleshoot
Fan Running At High
Speed
Is
Fault Code Troubleshoot
03-NN Yes Fault Code
Active 03-NN
?
No
Contact EMP
Support

Troubleshoot JW Fans Running At High Speed
Description JW fans are always running at high speed
Possible Causes  Loss of system temperature measurement
 Loss of EMP-Link communication’
 High transmission temperature
 Low engine coolant temperatures
References
Diagnostic Procedures:  Check FiL-11 Fan Continuity
 Determine If Transmission Fan Command Is Enabled
 Check Transmission Cooling Request
 Check Coolant Sensor Resistance
 Check TMC J1939 Communications
Referenced By:

Troubleshoot
JW Fans Running At
High Speed
Is
Active 08-NN
?
No
Is
Active 09-NN
?
No
Is
Active 03-NN
?
No
Should
Determine If
Check Transmission Non- Transmission Be
Transmission Fan Enabled No Done
Cooling Request Zero Cool
Command Is Enabled
?
Disabled
Yes
Troubleshoot High
Contact EMP
Zero Transmission
Support
Temperature

Troubleshoot CAC Fans Running At High Speed
Description CAC fans are always running at high speed
Possible Causes  Loss of system temperature measurement
 Loss of EMP-Link communication’
 High transmission temperature
References
 Troubleshoot TMC EMP-Link Communication
Diagnostic Procedures:  Check Transmission Cooling Request
 Check FiL-11 EMP-Link Continuity
 Check Charge Air Sensor Resistance
 Inspect Charge Air Sensor Connector
 Check Charge Air Sensor Harness Continuity
 Check TMC J1939 Communications
Referenced By:

Troubleshoot
CAC Fans Running At
High Speed
Is
Active 08-NN
?
No
Is
Active 09-NN
?
No
Is
Active 03-NN
?
No
Is
Active 07-NN
?
No
Contact EMP
Support

Troubleshoot Fan Runs When Ignition Off
Description A fan is running when ignition is off
Possible Causes  Failed system wakeup
 Failed FiL-11 connector
 Failed TMC Grey 12 pin connector
 Battery Drain
References
Troubleshooting Procedures:  Troubleshoot System Wakeup
Diagnostic Procedures:  Determine If Engine Shutdown Is Required
 Check System Wakeup Not Shorted To Power
 Inspect FiL-11 Connector
 Inspect TMC Grey 12 Pin Connector
Referenced By:  Troubleshoot Fan Runs When Engine Off

Troubleshoot
Fan Runs When Ignition
Off
Is
Determine If Engine
Engine Running Yes Yes Done
Shutdown Is Required
?
No
No
Check
Troubleshoot
System Wakeup Fail
System Wakeup
Voltage
Pass
Check Inspect
Repair FiL-11
System Wakeup Not Fail FiL-11 Connector Fail
Connector
Shorted To Power (All Fans)
Pass
Inspect Repair TMC

Pass TMC Grey 12 Pin Fail Grey 12 Pin
Connector Connector
Pass
Contact EMP Replace Main

Support Harness

Troubleshoot Fan Runs When Engine Off

Description A fan is running when the engine is off
Possible Causes  Failed ignition circuitry
 Failed J1939 engine speed communication
Possible Effects  Battery Drain
References
Diagnostic Procedures:  Determine If Engine Communication Is Required
Referenced By:

Troubleshoot
Fan Runs When Engine
Off
Is
Active 03-NN
?
No
Troubleshoot
Is Ignition On
No Fan Runs When Ignition
?
Off
Yes
Determine If Engine
Communication Is No Done
Required
Yes
Check
Fail
Pass
Check
TMC J1939 Fail
J1939 Connection
Communication
Pass
Contact EMP
Support

Troubleshoot TMC Not Functioning
Description TMC controller is not functioning
Possible Causes  Failed system electrical inputs
 Failed TMC Grey 12 pin connector
 Failed TMC wakeup input
 Failed TMC power input
 Failed TMC ground input
 Failed TMC Fuse
Possible Effects  Visual fault code indication not available
 Fans run at default speed
References
Troubleshooting Procedures:  Troubleshoot System Not Functioning
Diagnostic Procedures:  Check If TMC Is Operating
 Check Default Fan Operation
 Inspect TMC Communication Connector
 Check TMC Power Voltage
 Check TMC Fuse
Referenced By:  Troubleshoot FiL-11 Fan Communication

Troubleshoot
TMC Not Functioning
Check
Pass Done
If TMC Is Operating
Fail
Check Troubleshoot
Fail
Default Fan Operation System Not Functioning
Pass
Inspect Replace TMC

Fail
TMC Fuse Fuse
Pass
Inspect Repair TMC

TMC Grey 12 Pin Fail Grey 12 Pin
Connector Connector
Pass
Check TMC Wakeup Troubleshoot

Fail
Voltage TMC Wakeup
Pass
Check TMC Power Troubleshoot

Fail
Voltage TMC Power
Pass
Replace
TMC

Troubleshoot System Not Functioning
Troubleshoot System Not Functioning

Description Cooling system is not functioning
Possible Causes  TMC not operating
 Failed system power
 Failed system wakeup
References
Troubleshooting Procedures:  Troubleshoot TMC Not Functioning
Diagnostic Procedures:  Check Default Fan Operation
Referenced By:  Troubleshoot TMC Not Functioning

Troubleshoot LED Not Functioning

Description LED never turns on or is always on
Possible Causes  Failed pushbutton
 Failed LED
 Incorrectly installed LED
 Failed pushbutton/LED connector
 Failed TMC Black 12 Pin connector
 Failed pushbutton/LED harness
Possible Effects  Visual fault code indication not available
 Lamp test fails
References
Troubleshooting Procedures:  Troubleshoot Pushbutton Not Functioning
Diagnostic Procedures:  Test Pushbutton
 Test LED Operation
 Verify LED Polarity
 Inspect Pushbutton LED Connector
 Inspect TMC Sensor Connector
 Test LED Socket Voltage
 Check Main Wiring Harness LED Voltage
 Check TMC LED Output
Referenced By:

Troubleshoot
LED Not Functioning
Is the LED
On or Off
?
Off
Troubleshoot
Test Pushbutton Fail Pushbutton Not
Functioning
Pass
Test Replace
Pass
On LED Socket Voltage LED
Test LED Operation Pass Done
Fail
Fail Check Replace
Main Harness LED Pass Pushbutton
Verify Correct LED Voltage LED Harness
Fail
LED Polarity Polarity
Fail
Pass
Test Replace
Pass
Inspect Repair TMC LED Output Main Harness
Pushbutton LED Fail Pushbutton
Connector LED Connector Fail
Pass
Pass Replace
Inspect TMC
Repair TMC Black
TMC Black 12 Pin Fail
12 Pin Connector
Connector

Troubleshoot Pushbutton Not Functioning
Description Pushbutton has no effect on system
Possible Causes  Failed pushbutton/LED connector
 Failed TMC Grey 12 Pin connector
 Failed pushbutton/LED harness
Possible Effects  Fan Reversal feature not available
 LED test feature not available
References
Diagnostic Procedures:  Test Pushbutton
 Inspect Pushbutton LED Connector
 Inspect TMC Communications Connector
 Check Pushbutton Continuity
 Check Pushbutton Continuity Through Main Harness
Referenced By:  Troubleshoot LED Not Functioning
 Troubleshoot Un-Commanded Fan Reversal

Troubleshoot
Pushbutton Not
Functioning
Test Pushutton Pass Done
Fail
Inspect Repair
Pushbutton LED Fail Pushbutton
Connector LED Connector
Pass
Inspect
Repair TMC Grey
TMC Grey 12 Pin Fail
12 Pin Connector
Connector
Pass
Replace
Check
Fail Pushbutton
Pushbutton Continuity
LED Harness
Pass
Check
Replace Main
Pushbutton Continuity Fail
Harness
Through Main Harness
Pass
Replace
TMC

Troubleshoot LED Flashing
Troubleshoot LED Flashing
Description A fault condition has been detected by the system
Possible Causes  Any condition that will cause a fault code to be detected
by the system
Possible Effects  See associated fault code troubleshooting procedure
References
Troubleshooting Procedures:  Reference individual fault code troubleshooting
procedures
Diagnostic Procedures:  Read Fault Code From LED
Referenced By:

Troubleshoot J1939 Diagnostic Port Wiring
Troubleshoot J1939 Diagnostic Port Wiring
Description Unable to communicate with system using EMPower Connect
Service Tool due to wiring issues
Possible Causes  Failed diagnostic connector
 Failed diagnostic port wiring or connections
Possible Effects  Unable to perform EMPower Connect service tool
functions
References
Diagnostic Procedures:  Inspect Diagnostic Connector
 Check Diagnostic Connector J1939 Continuity
 Check Diagnostic Connector Voltage
Referenced By:  Troubleshoot Service Tool Communication
Troubleshoot
J1939 Diagnostic Port
Wiring
Repair
Inspect
Fail Diagnostic
Diagnostic Connector
Connector
Check
Diagnostic Connector Fail
J1939 Continuity
Pass
Check Repair
Diagnostic Connector Fail Diagnostic Port
Voltage Wiring
Pass
Contact EMP
Support

Troubleshoot Service Tool Communication
Description Unable to communicate with system with EMPower Connect
Service Tool
Possible Causes  TMC not functioning
 Failed communication wiring to TMC
 Failed vehicle J1939 wiring
 Failed J1939 diagnostic connector port
Possible Effects  Unable to perform EMPower Connect service tool
functions
References
Troubleshooting Procedures:  Troubleshoot TMC Not Functioning
 Troubleshoot J1939 Diagnostic Port Wiring
Diagnostic Procedures:  Check If TMC Is Operating
Referenced By:

Troubleshoot
Service Tool
Communication
Check Troubleshoot
Fail
If TMC Is Operating TMC Not Functioning
Pass
Is
Active 03-NN
?
No
Troubleshoot
Check
Fail J1939 Diagnostic Port
Wiring
Pass
Check Troubleshoot
TMC J1939 Fail Vehicle J1939
Communication Connection
Pass
Contact EMP
Support

Troubleshoot Un-Commanded Fan Reversal
Troubleshoot Un-Commanded Fan Reversal
Description Fans reverse when not commanded to do so
Possible Causes  Pushbutton interference
 J1939 fan reversal command
Possible Effects  Undesired fan reversal
References
Troubleshooting Procedures:  Troubleshoot Pushbutton Not Functioning
Diagnostic Procedures:  Check Pushbutton For Interference
 Determine If J1939 Fan Reversal Was Commanded
Referenced By:
Troubleshoot
Un-Commanded Fan
Reversal
Check Remove
Pushbutton For Fail Pushbutton
Interference Interference
Pass
Determine If J1939 Fan

Reversal Was Yes Done
Commanded
No
Troubleshoot
Pushbutton Not
Functioning

______________ Diagnostic Codes
Diagnostic Procedures

Check Battery Voltage
Verify that the electrical supply system is being maintained at the correct level. The nominal level is
usually determined by the battery manufacturer and is usually specified to be between 27-29V when
the engine is running and the alternator is enabled.
This test is run with active exposed voltages. Care must be taken to not connect positive voltages
to a ground wire or to the vehicle chassis during this test. Doing so may cause sparks, blow a fuse or
damage wiring.
1. Start the engine

2. Ensure alternator is enabled
3. Measure voltage across the 24V battery system.
Result Diagnosis
26.0 – 30.0 Volts Pass
< 26.0 Volts Fail Low
> 30.0 Volts Fail High
Referenced by:

 Troubleshoot High Voltage

Check FiL-11 Address Resistance

Verify that the correct address resistance is connected to the corresponding controller and the
associated wiring between the FiL-11 Fan and resistor is intact. The address resistor defines which
EMP-Link address is used on the EMP-Link data link by each fan controller. This allows identical
controllers to be used within the system. The absence of an address resistor will cause a controller to
operation at a default fan speed. An incorrect address will cause a controller to respond to the
incorrect command and report speed for an incorrect fan location.
Remove all voltage from the system prior to performing this procedure.
1. Remove the 7 pin Delphi connector from the Fan

2. Measure resistance across pin A and pin F of the Wiring Harness connector
Result Diagnosis
Resistance Within ‘Valid Range’ Specified in Table 1 Pass
All other conditions Fail
Table 1: Controller Address Resistor Values

Controller Nominal Value Valid Range (+/-2%)
Location (Ohms) (Ohms)
1 Open
2 0 0-55
3 1100 1078-1122
4 2490 2440-2540
5 4320 4234-4406
6 6650 6517-6783
7 10000 9800-10200
8 15000 14700-15300
7 Pin Harness Pin F

Connector
Referenced by: Pin A
 Troubleshoot FiL-11 Communication

Check FiL-11 Power Voltage

Verify that the proper electrical supply is provided to a fan.
damage wiring.
1. Start the engine

3. Remove the 7 pin Delphi connector from the FiL-11 Fan in question
4. On the harness measure the voltage across pin E (positive) and pin G (negative)
Result Diagnosis
2.0 to 26.0 Volts Fail Low
26.0 - 30.0 Volts Pass
Pin E
FiL-11 Interface
Connector
Pin G
Referenced by:


Check FiL-11 Wakeup Voltage

Verify that the proper electrical supply is provided to the wakeup input of a fan controller.
damage wiring.
1. Start the engine

3. Ensure wakeup voltage is provided to the cooling system. In some applications, this requires
the engine to be running.
4. Remove the 7 pin Delphi connector from the FiL-11 Fan
5. On the harness measure the voltage across pin C (positive) and pin G (negative)
Result Diagnosis
< 4.0 Fail Low
13.5 or 27 Volts Nominal
Pin G
FiL-11 Interface
Connector
Pin C
Referenced by:
 Troubleshoot FiL-11 Wakeup


Check TMC Power Voltage

Verify that the proper electrical supply is provided to the system controller.
damage wiring.
1. Start the engine

3. Remove the 12 Pin Grey Deutsch connector from the TMC controller
4. Measure voltage across pin 12 (positive) and pin 1 (negative) of the TMC connector
Result Diagnosis
<9.0 volts Fail Zero
13.5 or 27 Volts Nominal
Pin 1
TMC Grey
Connector
Pin 12
Referenced by:


Check TMC Wakeup Voltage

Verify that the proper electrical supply is provided to the wakeup input of the system controller.
damage wiring.
1. Start the engine

4. Remove the 12 Pin Grey Deutsch connector from the TMC controller
5. Measure voltage across pin 11 (positive) and pin 1 (negative) of the TMC connector
Result Diagnosis
<9.0 volts Fail Zero
13.5 or 27.0 Volts Nominal
Pin 1
Grey TMC
Connector
Referenced by: Pin 11


Check Controller Fuse

Verify that the fuse is in good operational condition and is not blown. Fuse locations for
corresponding controllers are shown in the Kit Fuses section under Service Parts Replacement.
1. Remove the fuse from the fuse holder

2. Measure resistance across the two pins of the fuse
Result Diagnosis
<.5 Ohms Pass
TMC & FiL-11 Fuses TMC & FiL-11Fuses
MH8-5031/5034 MH8-4336
Referenced by:


Perform Test Drive
Verify cooling performance of the system
1. Connect the EMPower service tool to a 9 pin vehicle diagnostics connector and establish
communication between the EMPower Connect service tool software and the cooling system.
2. Drive the vehicle
3. Observe temperatures using the Dash display of the EMPower Connect service tool and verify
that temperatures remain within the normal operating range
4. Verify no over-temperature fault codes are set using the Diagnostic display of the EMPower
Connect service tool
Result Diagnosis
Temperatures remain within the normal operational range AND no Pass
over-temperature fault codes are set
Dash Display
JW Temperature CAC Temperature
Referenced by:


Check FiL-11 Fan Operation

Verify that a controller and respective fan is functional.
USING EMPower Connect Service Tool
3. Using the manual controls available on the Dash display of the EMPower Connect service tool,
command the fans to forward operation.
4. Visually verify that the fan is operational
USING Fan Reverse Button
Do not stand in the airflow path when reversing fans. Debris exiting the system may cause injury.
Ear protection is recommended during this procedure.
2. Stand clear of the airflow path and press the fan reverse button.
3. After the fan reversal is complete, visually inspect the fan for proper operation during the “slow
forward” step of the fan reverse cycle.
Result Diagnosis
The fan is operational Pass
Dash Display
Manual Fan Speed

Override
Referenced by:


Check Default Fan Operation

Verify that the FiL-11 Fans are able to function in default mode when unable to receive an EMP-Link
speed command from the TMC controller.
damage wiring.
1. Disconnect the 12 pin Grey Deutsch TMC Controller Connector

3. Visually verify that all fans turn on and spin at the 4000 RPM default speed
Result Diagnosis
The fan is operational Pass
Grey TMC
Connector
Referenced by:


Test Maximum Fan Performance

Verify all fans are capable of reaching their maximum performance level.
1. Run the engine at a speed greater than 1500 RPM.

3. Using the manual controls available on the Dash display of the EMPower Connect service tool,
command the fans to run forward at 5500 RPM operation.
4. Observe all reported fan speeds from the Dash display of the EMPower Connect service tool
Result Diagnosis
All reported fan speeds are greater than 5250 RPM Pass
Dash Display
Enter 5500 for

Manual RPM
Manual Fan Speed

Override
Referenced by:


Check System Wakeup Voltage

Verify that the proper electrical supply is connected to the wakeup input of the cooling system.
damage wiring.
1. Start the engine

2. Disconnect the cooling system wakeup signal connector
3. Apply electrical power so that the cooling system would normally operate. In some
applications, this requires the engine to be running.
4. Measure voltage from the vehicle side of the cooling system wakeup signal connector
(positive) and the negative stud (ground) of the cooling system
Result Diagnosis
<26.0 volts Fail Low
Single pin system

Wakeup connector
Referenced by:


Check System Voltage

Verify that the proper electrical supply is connected to the cooling system.
damage wiring.
1. Start the engine

3. Measure voltage across the positive and negative input studs of the cooling system.
Result Diagnosis
Positive and Negative

24V input studs
Referenced by:


Check System Ground Continuity

Verify proper connection of the system ground lug to the negative battery terminal
1. Measure resistance between the negative stud of the cooling system and the vehicle frame or
the negative stud of the 24V battery system
Result Diagnosis
<.5 Ohms Pass
Referenced by:

Check System Fuse

Verify that the fuse is in good operational condition and is not blown
1. Remove the 250 Amp fuse from the fuse holder typically located at the back of the alternator
2. Measure resistance across the two ends of the fuse
Result Diagnosis
<.5 Ohms Pass
250 Amp system

fuse
Referenced by:

Check System Wakeup Not Shorted To Power

Verify that the cooling system wakeup is not shorted to power within the cooling system.
damage wiring.
1. Disconnect the cooling system single pin Delphi WeatherPack wakeup signal connector
2. Apply electrical power to the cooling system by enabling vehicle power.
3. Measure voltage from the cooling system side of the cooling system wakeup signal connector
(positive) to the negative stud (ground) of the cooling system
Result Diagnosis
<2.0 volts Pass
Single pin system

Wakeup connector
Negative Ground
Stud
Referenced by:

Test Thermostat Operation
Verify that the engine thermostat is correctly permitting and blocking coolant flow to the radiator.
1. Turn off the engine and allow the engine to cool below the thermostat close temperature
2. Start the engine
4. View the Dash Display of the EMPower Connect service tool software
5. Verify that the EMP coolant temperature sensor is measuring temperatures less than the
engine J1939 reported coolant temperature during warmup (verifying that the thermostat is
closed)
6. Allow the engine to warm up until the J1939 reported coolant temperature is greater than the
thermostat fully open temperature
7. Verify that the EMP coolant temperature sensor is measuring nearly the same temperature as
the engine J1939 reported coolant temperature (verifying that the thermostat is open)
Result Diagnosis
Open and closed thermostat operation has been verified Pass
Dash Display
J1939 Reported
Coolant Temp
EMP Coolant Temp
Referenced by:


Check Vehicle Wakeup Source Voltage

Verify that the correct source voltage is applied by the vehicle to the cooling system
damage wiring.
1. Start the engine

4. Measure the voltage at the location on the vehicle at the source of the wakeup signal which
feeds the wakeup input of the cooling system.
Result Diagnosis
Referenced by:

Check Vehicle J1939 Continuity

Verifies continuity to the vehicle J1939 backbone.
Remove all voltage from the vehicle prior to performing this procedure.
1. Remove all voltage to the vehicle

2. Disconnect the cooling system 3 pin Deutsch DT J1939 connector
3. Measure resistance across the pins 1 and 2 on the vehicle side of the connector
Result Diagnosis
<50 Ohms Fail
50 - 70 Ohms Pass
>70 Ohms Fail
Vehicle 3 Pin
J1939 Connector
Referenced by:

Check TMC J1939 Continuity
Verify that a TMC controller is properly connected to the Vehicle J1939 communication link.
1. Remove the 12 pin Deutsch connector from the TMC controller

2. Measure resistance across pin 5 and pin 6 of the communication connector
Result Diagnosis
<50 Ohms Fail
50-70 Ohms Pass
>70 Ohms Fail
TMC
Pin 5
12 Pin Grey
Connector
Pin 6
Referenced by:

Check FiL-11 EMP-Link Continuity

Verify that a Fan is properly connected to the TMC via the EMP-Link communication link.
Verify that a Fan is properly connected to the eLink communication link.
1. Remove the 7 pin Delphi connector from the FiL-11 Fan in question
2. Remove the Grey 12 pin Deutsch Connector from the TMC controller
3. Check continuity on the EMP-Link signal line from pin D on the FiL-11 connector to pin 4 on
the Grey 12 pin TMC connector
4. Check continuity on the EMP-Link signal return line from pin F on the FiL-11 connector to pin 2
on the TMC connector
Result Diagnosis
<2 Ohms Pass
>2 Ohms Fail
Pin F
Pin 2
Pin 4
7 Pin FiL-11 Pin D 12 Pin Grey Comm

Connector Connector
Referenced by:


Check If TMC Is Operating

Verifies that the TMC is operating.
Check A – Startup
1. Power up the system, observing the cooling system diagnostic LED during power up process.
2. If the cooling system diagnostic LED illuminates for two seconds during the power up process,
then the TMC is operating
Fan Reversal Diagnostic

Switch LED
Check B – Fan Reversal
1. Start the engine

4. Press the fan reverse button
5. If the cooling system diagnostic LED illuminated when the reverse button is pressed or if the
fans begin reverse operation then the TMC is operating

Check C – Fan Commands
1. Turn off the engine and allow the engine to cool below temperatures that would normally
require fan operation
2. Start the engine
5. Remove the Grey 12 pin Deutsch TMC communication connector
6. If fans change speed five seconds following removal of the TMC communication connector,
then the TMC is operating.
12 Pin Grey Comm

Connector
Check D – EMPower Connect Service Tool Communications

1. Start the engine
4. Attempt to establish communication between the EMPower Connect service tool software and
the cooling system
5. If communications is established, then the TMC is operating
Result Diagnosis
Check A, B, C or D indicate the TMC is operating Pass
Referenced by:
 Troubleshoot TMC Communication


Check TMC J1939 Communication

Verifies that the TMC is communicating on the J1939 data link.
1. Start the engine
4. Connect the EMPower service tool to a 9 pin vehicle diagnostics connector and attempt to
establish communication between the EMPower Connect service tool software and the cooling
system.
5. If communications is established, then the TMC is communicating on the J1939 data link
Result Diagnosis
EMPower Connect service tool communications established Pass
Referenced by:


Test TMC Coolant Input Circuit

Verify that the controller coolant sensor input circuitry is correct.
damage wiring.
1. Remove all voltage from the system

2. Disconnect the Black 12 pin Deutsch sensor connector from the TMC controller
3. Insure Grey 12 pin Deutsch connector remains plugged into TMC controller
4. Place a 1.0 kOhm resistance across pin 1 and pin 6 of TMC sensor connector port
5. Reconnect voltage to the system
6. Start the engine
10. Using the Dash display of the EMPower Connect service tool software, observe the value
calculated by the TMC controller
Result Diagnosis
<181.4 degF (<83 degC) Fail
181.4 – 188.6 degF (83-87 degC) Pass
>188.6 degF (>87 degC) Fail
Pin 1
Dash Display
Pin 6 EMP Coolant Temp

Referenced by:

 Troubleshoot Coolant Sensor Measurement

Test TMC Charge Air Input Circuit

Verify that the controller coolant sensor input circuitry is correct.
damage wiring.
1. Remove all voltage from the system

2. Disconnect the Black 12 pin Deutsch sensor connector from the TMC controller
3. Insure Grey 12 pin Deutsch connector remains plugged into TMC controller
4. Place a 1.0 kOhm resistance across pin 1 and pin 7 of TMC sensor connector port
5. Reconnect voltage to the system
6. Start the engine
10. Using the Dash display of the EMPower Connect service tool software, observe the value
calculated by the TMC controller
Result Diagnosis
<116.6 degF (<47 degC) Fail
116.6 – 123.8 degF (47-51 degC) Pass
>123.8 degF (>51 degC) Fail
Pin 1
Dash Display
Pin 7 EMP CAC Temp
Referenced by:

Verify J1939 Coolant Temperature Received

Verify that the cooling system is receiving the J1939 coolant temperature
1. Start the engine

5. Using the Dash display of the EMPower Connect service tool software, observe the value of
ECU Coolant Temp within the J1939 Data area.
Result Diagnosis
ECU Coolant Temp > -40 Pass
Dash Display
ECU Coolant Temp
Referenced by:

Compare Coolant Measurements
Verify that the engine and the cooling system measurements of coolant temperature are nearly the
same.
1. Start the engine

ECU Coolant Temp within the J1939 Data area.
6. Allow the engine to warm up until the J1939 reported coolant temperature is greater than the
thermostat fully open temperature
7. Compare the ECU Coolant Temp field within the J1939 Data area to the Water temperature
indicator
Result Diagnosis
Temperature difference less than 3.6 DegF (2 degC) Pass
Dash Display
ECU Coolant Temp
EMP Coolant Temp
Referenced by:


Inspect Air Flow Path For Obstructions

Verify that the air flow path leading to the heat exchanger and from the heat exchanger is clear and
free of obstructions.
1. Verify that the fresh air flow path of ambient air leading to the heat exchanger is free of debris,
ice, mounted equipment or other obstructions
2. Verify that the hot air exhaust flow path on the back side of the heat exchanger is free of
debris, mounted equipment or other obstructions.
Result Diagnosis
All above inspections indicate that air can freely flow to and from the Pass
heat exchanger
Referenced by:

Check Coolant Level

Verify that the engine coolant level is set correctly per the vehicle manufacturer’s procedure.
Result Diagnosis
Coolant level is set correctly Pass
Referenced by:
Check Coolant Mixture

Verify that the engine coolant mixture of coolant and water is set correctly per the vehicle
manufacturer’s procedure.
Result Diagnosis
Coolant mixture is set correctly Pass
Referenced by:

Check Cooling System Deaeration

Verify that the engine coolant system has been deaerated correctly to ensure that all air has been
purged from the system per the vehicle manufacturer’s procedure.
1. Verify that all air has been purged from the system following the manufacturer’s procedure
2. Verify coolant is visible in the overflow site glass
3. Verify coolant in the site glass is not milky indicating that there could be an air leak within the
system
Result Diagnosis
Coolant system is free of air Pass
Referenced by:
Check Transmission Fluid Level

Verify that the transmission fluid level is set correctly per the transmission manufacturer’s procedure.
Result Diagnosis
Fluid level is set correctly Pass
Referenced by:

Inspect FiL-11 Connector Power Pins

Verify the integrity of the connector by visual inspection.
Inspect the external and internal portions of the 7 pin Delphi connectors as follows:
1. Verify connector is properly seated and latched into place

2. Verify the internal cavity of connector is clean and dry
3. Inspect pins and sockets E (positive) and G (negative) on fan and harness connectors to
insure that they are clean and free of corrorsion
4. Verify the connector pins are fully engaged and locked in place
5. Verify the integrity of the crimp of each pin to each wire
6. Verify the stripped portion of the wire connected to the pin is clean, dry, and free of corrosion
Result Diagnosis
All above inspections indicate a proper connection Pass
Pin G Pin G
(Ground) (Ground)
Pin E
(Positive)
Referenced by:

 Troubleshoot FiL-11 Wakeup

Inspect FiL-11 Wake Up Pin

3. Inspect pin and socket C on fan and harness connectors to insure that they are clean and free
of corrorsion
Result Diagnosis
Pin C
Referenced by:

 Troubleshoot Fan Slow Or Not Running

Inspect FiL-11 Connector Communication Pins

3. Inspect pins and sockets D (EMP-Link) and F (EMP-LINK Return) on fan and harness
connectors to insure that they are clean and free of corrorsion
Result Diagnosis
Pin F Pin D Pin F

(EMP-Link Return) (EMP-Link) (EMP-Link Return)
Referenced by:


Inspect Address Resistor Connector

Inspect the external and internal portions of the 2 pin Delphi 150 M/P connector as follows:

2. Verify the internal cavity of connector is clean, dry and free of corrosion
3. Verify connector pins are properly seated and latched into place
4. Verify all connector pins are clean, dry and free of corrosion
5. Verify the connector pin retainer is holding the pins in place
Result Diagnosis
Address
Examine Pins
Resistor
`` And Connections
Connector
Referenced by:


Inspect TMC Sensor Connector

Inspect the external and internal portions of the Black 12 pin Deutsch connector as follows:

3. Remove the orange wedge lock with a small screwdriver and verify connector pins are properly
seated and latched into place
Result Diagnosis
Black 12 Pin Remove Wedge Lock And

Sensor Connector Examine Pins And Connections
Referenced by:

 Troubleshoot LED Not Functioning

Inspect TMC Power Connections

Inspect the external and internal portions of the Grey 12 pin Deutsch TMC connector as follows:

3. Remove the orange wedge lock with a small needle nose pliers and verify connector pins
are properly seated and latched into place
4. Inspect pins and sockets 12 (Positive) and 1 (Ground) on TMC connector to insure that they
are clean and free of corrosion
7. Verify the stripped portion of the wire connected to the pin is clean, dry, and free of
corrosion
Result Diagnosis
TMC
Controller
12 Pin Grey TMC Pin 1 Pin 12

Connector (Ground) (Power)
References:


Inspect TMC Wake Up Pin
Inspect the external and internal portions of the Grey 12 pin Deutsch connectors as follows:

3. Remove the orange wedge lock with a small needle nose pliers and verify connector pins are
properly seated and latched into place
4. Inspect pins and sockets 11 (Positive) and 1 (Ground) on TMC connector to insure that they
are clean and free of corrosion
Result Diagnosis
TMC
Controller
12 Pin Grey TMC Pin 1 Pin 11

Connector (Ground) (Ignition)
Referenced by:

 Troubleshoot Fan Slow Or Not Running

Inspect TMC Communication Connector
Inspect the external and internal portions of the connector as follows:

3. Remove the orange wedge lock with a small needle nose pliers and verify connector pins are
properly seated and latched into place
Result Diagnosis
Grey 12 Pin Comm Remove Wedge Lock And

Connector Examine Pins And Connections
Referenced by:

 Troubleshoot Pushbutton Not Functioning
 Troubleshoot TMC Wake Up

Inspect Charge Air Sensor Connector
Inspect the external and internal portions of the 2 pin Delphi GT150 connector as follows:

Result Diagnosis
CAC Sensor Examine Pins

Connector And Connections
Referenced by:

Inspect Pushbutton LED Connector

Inspect the external and internal portions of the 4 pin Delphi 150 M/P connector as follows:

Result Diagnosis
Pushbutton/LED Examine Pins

Connector And Connections
Referenced by:


Inspect Diagnostic Connector

Inspect the external and internal portions of the 9 Pin J1939 Diagnostics connector as follows:
Result Diagnosis
9 Pin J1939
Diagnostics Connector
Referenced by:

Inspect Charging System Connections
Verify the integrity of the connections of the charging system. The charging system wiring will vary
from installation to installation.
Inspect all charging system connections as follows:
1. Verify all connections are properly seated and all lugs tight
2. Verify all connections are free of corrosion
3. Verify the integrity of the crimp of each terminal to each wire
4. Verify the stripped portion of the wire connected to each terminal is free of corrosion
5. Verify all insulation is free of cracking and chafing
Result Diagnosis
All above inspections indicate proper connections Pass
Referenced by:
Check Controller Environmental Conditions

Verify the proper mounting location of a controller.
Inspect the mounting location for:
1. Objects contacting the controller that could reach high temperatures

2. Objects in close proximity of the controller that could reach high temperatures
3. Surrounding air that could reach high temperatures
4. Objects or dirt build up that could prevent heat transfer out of the controller to the surrounding
air
Result Diagnosis
No contacting objects, objects in close proximity, or surrounding air Pass
exceeding 220 degF (105 degC) AND nothing is preventing heat transfer
out of the controller to the surrounding air
References:


Inspect Coolant Sensor Connector
Inspect the external and internal portions of the 2 pin Delphi 150 GT connector as follows:

Result Diagnosis
EMP Coolant Sensor Examine Pins

And Connections
Referenced by:


Inspect Heat Exchanger for Cleanliness

Verify that the heat exchanger is clean and able to function at peak performance.
Inspect the heat exchanger as follows:
1. Verify that the heat exchanger is free of debris, ice, or other objects that may prevent
the passage of airflow through it
2. Verify that the fins of the heat exchanger are not plugged or coated with dirt, grease, or
oil
Result Diagnosis
inspections indicate that the heat exchanger is able to function properly Pass
conditions Fail
Referenced by:


Inspect Intake Air For Leaks
Verify that there are no leaks within the engine intake air system.
Result Diagnosis
No air leaks Pass
Referenced by:
Inspect Recirculation Prevention

Verify that the hardware is in place and functioning properly to prevent recirculation of hot exhaust air
exiting the heat exchanger from returning to the fresh ambient air intake of the heat exchanger.
Inspect the recirculation preventions as follows:
1. Verify that all door seals are properly seating against the door
2. Verify that all seals between the heat exchanger are in place and in good condition
3. Verify that any skirting mounted to the underside of the body are in place and in good
condition
4. Verify that any engine compartment vented doors are in place and free of obstruction
5. Verify that air flow through the engine compartment has not been obstructed by debris
or mounted equipment
Result Diagnosis
All above inspections indicate that the recirculation preventions are in Pass
place and in good condition
Referenced by:


Inspect System J1939 Connector
Inspect the external and internal portions of both halves of the 3 pin Deutsch DT connector as follows:

7. Verify the stripped portion of the wire connected to the pin is clean, dry, and free of
corrosion
Result Diagnosis
System 3 Pin Vehicle 3 Pin J1939

J1939 Connector Connector
Referenced by:
 Troubleshoot TMC Communication


Inspect System Wakeup Connector
Inspect the external and internal portions of both halves of the single pin Delphi WeatherPack
connector as follows:

Result Diagnosis
System Single Pin

Wakeup Connector
Referenced by:


Inspect Fuse Holder
Verify the integrity of the fuse holder and connections by visual inspection.
Inspect the external and internal portions of the fuse holder as follows:

Result Diagnosis
FiL-11/TMC Controller Examine Contacts

Fuses Holders And Connections
Referenced by:


Inspect Lug Connections
Verify the integrity of the lug connections by visual inspection.
Inspect the lug connections as follows:
1. Verify all connections are properly seated and all lugs tight
2. Verify all connections are free of corrosion
3. Verify the integrity of the crimp of each terminal to each wire
4. Verify the stripped portion of the wire connected to each terminal is free of corrosion
5. Verify all insulation is free of cracking and chafing
Result Diagnosis
Examine Connections And

Crimps To Insure They Are
Secure And Clean
Referenced by:


Check Charge Air Sensor Resistance
Verify operation of the charge air temperature sensor.
Note: This procedure is only valid at temperatures greater than 32 degF (0 degC)
1. Remove the charge air temperature sensor connector from the sensor
2. Measure the resistance across the pins of the charge air temperature sensor and
compare the measured value to the expected value for reasonableness.
Result Diagnosis
Measured resistance is near the expected value within Table 2 Pass
Table 2: Charge Air Sensor Resistance

Charge Air Temperature Resistance
DegF DegC Ohms

32 0 9260
50 10 5570
68 20 3460
86 30 2210
104 40 1440
122 50 965
140 60 660
158 70 462
176 80 329
Remove Connector And

Measure Resistance
Between Pins on CAC
Sensor
Referenced by:

Check Charge Air Sensor Harness Continuity

Verify the electrical continuity of the charge air temperature sensor wiring.
1. Remove the larger Black 12 pin Deutsch sensor connector from the TMC controller
2. Measure the resistance between pin 1 and pin 7 of the wiring harness connector and compare
the measured value to the expected value using the table above for reasonableness
3. Verify there is no continuity from pin 1 of the wiring harness to vehicle chassis ground
Result Diagnosis
Measured resistance is near the expected value within Table 3 AND Pass
the continuity checks above were verified as correct.
TMC Black 12 Pin Deutsch Measure Resistance

Sensor Connector Between Pins 1 & 7
Referenced by:

Check Location Of Charge Air Sensor
Verify the charge air temperature sensor is installed on the correct port of the CAC heat exchanger.
1. Locate the CAC port that the charge air temperature sensor is installed in.
2. Follow the CAC pipe attached to the port with the CAC sensor installed over to the
engine and insure that attaches to the engine intake manifold
3. If CAC sensor is installed on the outlet of the turbo it is installed in the wrong location
and must be moved.
Result Diagnosis
CAC sensor installed on engine intake manifold side of heat exchanger Pass
CAC sensor on turbo side Fail
CAC Sensor
Sensor Could Be
Installed On Either
Side
Referenced by:


Check Coolant Sensor Resistance
Verify operation of the coolant temperature sensor.
Note: This procedure is only valid at temperatures greater than 32 degF (0 degC)
1. Remove the coolant temperature sensor connector from the sensor

2. Measure the resistance across the pins of the coolant temperature sensor and compare
the measured value to the expected value for reasonableness.
Result Diagnosis
Measured resistance is near the expected value within Table 3 Pass
Table 3: Coolant Sensor Resistance

Coolant Temperature Resistance
DegF DegC Ohms

32 0 33650
50 10 20180
68 20 12540
86 30 7990
104 40 5220
122 50 3500
140 60 2400
158 70 1670
176 80 1190
194 90 863
212 100 637
230 110 476
Remove Connector And

Measure Resistance
Between Pins on Coolant
Sensor
Referenced by:

Check Coolant Sensor Harness Continuity
Verify the electrical continuity of the coolant temperature sensor wiring.
1. Remove the Black 12 pin Deutsch sensor connector from the TMC controller
2. Measure the resistance between pin 1 and pin 6 of the wiring harness connector and
compare the measured value to the expected value for reasonableness
Result Diagnosis
Measured resistance is near the expected value within Table 3 AND Pass
the continuity checks above were verified as correct.
TMC Black 12 Pin Deutsch Measure Resistance

Referenced by:


Test Pushbutton
Verify the pushbutton functionality.
1. Start the engine

3. Ensure wakeup voltage is provided to the cooling system.
4. Press the fan reverse pushbutton
5. Observe for diagnostic LED illumination and fan reverse operation
Result Diagnosis
LED illuminates OR fans reverse in response to reverse pushbutton activation Pass
Fan Reversal Pushbutton Diagnostic LED
Referenced by:


Check Pushbutton Continuity

Verify the electrical continuity of the fan reverse pushbutton.
1. Disconnect the 4 pin Delphi 150 M/P pushbutton/LED harness assembly connector
2. With the pushbutton released, verify there is no continuity between pin C and pin D of the
pushbutton/LED harness assembly
3. With the pushbutton pressed, verify there is continuity between pin C and pin D of the
pushbutton/LED harness assembly
Result Diagnosis
No continuity observed with the pushbutton released AND continuity Pass
observed with the pushbutton pressed
4 Pin Delphi 150 M/P Connector Pins C and D
Referenced by:

Check Pushbutton Continuity Through Main Harness
Verify the electrical continuity of the main harness and fan reverse pushbutton.
1. Remove the Grey 12 pin Deutsch communication connector from the TMC controller
2. With the pushbutton released, verify there is no continuity between pin 8 and pin 9 of the
communication connector
3. With the pushbutton pressed, verify there is continuity between pin 8 and pin 9 of the
communication connector
Result Diagnosis
No continuity observed with the pushbutton released AND continuity Pass
observed with the pushbutton pressed
TMC Grey 12 Pin Deutsch Measure Resistance

Comm Connector Between Pins 8 & 9
Referenced by:

Check Pushbutton For Interference

Verify by inspection that no objects could be interfering with the fan reverse pushbutton and causing
the pushbutton to be pressed.
1. Inspect the area surrounding the pushbutton for objects that may contact the button
2. Inspect the door that closes over the pushbutton for objects that may be mounted on the door
that may come in contact with the button when the door is closed.
Result Diagnosis
No objects can contact the button Pass
Make Sure Nothing Is

Contacting Pushbutton
Referenced by:

Read Fault Code From LED
Read active fault codes from the blinking cooling system diagnostic LED.
The format of the fault code is:

XX-YY, where
XX is the first number of the fault code
YY is the second number of the fault code
The fault code is communicated by the LED as follows:
1. On for 4 seconds to indicate the start of the fault code list

2. Off for 2.5 seconds to indicate the start of a single code
3. A sequence of 0.5 second blinks. The number of these blinks indicates the first number (XX)
of the fault code.
4. Off for 1.25 seconds to indicate the start of the second digit of the fault code
5. A sequence of 0.5 second blinks. The number of these blinks indicates the second number
(YY) of the fault code.
6. If multiple fault codes are active, the next active fault code will be communicated beginning
with step 2. When all fault codes have been communicated, the fault code list will be repeated
beginning with the long On time of step 1.
Read Fault Codes From

Blinking Diagnostics LED
Referenced by:
 Troubleshoot LED Flashing

Test LED Operation
Verify operation of the cooling system diagnostic LED
1. Start the engine

Test A:
1. Press the fan reverse pushbutton
2. Observe for the LED to be turned on for 4 seconds immediately following the press of the
button
Test B:
2. Using the Manual Control area of the F3--Dash display of the EMPower Connect service tool
software, click on the LED override button to force the LED to be turned on
3. Verify that the LED is turned on
Result Diagnosis
LED turned on with either Test A or Test B Pass
Dash Display
LED Override
Press Fan Reversal Pushbutton

and LED Should Turn on For 4 Sec
Referenced by:

Check TMC LED Output
Verify that the TMC LED output circuitry is functioning correctly.
damage wiring.
1. Start the engine

4. Remove the Black 12 pin Deutsch connector from the TMC controller
5. Insure Grey 12 pin Deutsch connector remains connected to TMC.
6. Measure voltage output at the controller between pin 9 and pin 12.
7. Observe the voltmeter for a changing voltage between 5V and 0V as the controller attempts to
blink out fault code information.
Result Diagnosis
Voltage changing between 5V and 0V Pass
TMC Black 12 Pin Deutsch Measure Voltage

Referenced by:

Test LED Socket Voltage
Verify voltage is provided to the LED socket.
damage wiring.
1. Start the engine

5. Using the Manual Control area of the F3--Dash display of the EMPower Connect service tool
software, click on the LED override button to force the LED to be turned on
6. Remove the diagnostic LED from the socket.
7. Measure voltage across the terminals within the LED socket from the terminal aligned with the
red wire (positive) to the terminal aligned with the black wire
Result Diagnosis
Voltage > 3.5 V Pass
Dash Display
LED Override
Remove LED And Measure

Voltage Across Terminals
Referenced by:

Verify LED Polarity

Verify that the LED is installed into the socket with the correct polarity.
1. Inspect the polarity with which the LED is installed
Result Diagnosis
The small nub and red stripe on the side of the LED body is Pass
aligned with the red wire entering the back side of the socket
Referenced by:

Check Main Wiring Harness LED Voltage

Verify LED voltage is provided to the Fan Reversal/LED Bracket assembly.
damage wiring.
1. Start the engine

5. Disconnect the 4 pin Delphi 150 M/P pushbutton/LED harness assembly connector
6. Measure voltage from pin B (positive) to pin A (negative) on the TMC controller side of the
pushbutton/LED harness assembly connector.
Result Diagnosis
Voltage > 3.5 V Pass
4 Pin Delphi 150 M/P Connector Pin A Pin B
Referenced by:

Check Diagnostic Connector J1939 Continuity

Verify that the vehicle’s service tool diagnostic connector is properly connected to the J1939
communication link.
1. Measure resistance across pin C and pin D of the vehicle’s 9 Pin diagnostic connector
Result Diagnosis
<50 Ohms Fail
50-70 Ohms Pass
>70 Ohms Fail
Pin D
Pin C
9 Pin Diagnostics Connector
Referenced by:

Check Diagnostic Connector Voltage
Verify that the vehicle’s J1939 service tool diagnostic connector is properly connected to a power
source.
damage wiring.
1. Measure voltage across pin B (positive) to pin A (negative) of the vehicle’s 9 Pin J1939
diagnostic connector
Result Diagnosis
< 10V Fail
10-30V Pass
> 30V Fail
Pin A
Pin B
9 Pin Diagnostics Connector
Referenced by:

Inspect Fans
Verify the integrity of the fans and their mounting by visual inspection.
Inspect the fan as follows:

1. Blades are not missing
2. Blades do not have chips
3. Blades are not cracked
4. Blades are not touching the fan shroud
5. Blades are not obstructed from turning
6. Fan shroud is properly seated to cooling system
7. Fan shroud to cooling system mounting bolts are tight
Result Diagnosis
All above inspections indicate a properly functioning fan with Pass
proper mounting
Referenced by:


Check Engine Communication
Verify engine communications are available on the J1939 communication link
1. Start the engine

5. Open the J1939 Bus Monitor via the EMPower Connect service tool menu option of ‘Tools-
>CAN Bus Monitor’
6. Verify that messages are being displayed in the J1939 Bus Monitor window indicating proper
connection of the tool to the J1939 data link
7. Examine the ‘Src’ column for a value of 00 which is the J1939 recommended source address
for an engine
Result Diagnosis
00 exists within the ‘Src’ column of the J1939 Bus Monitor Pass
CAN Bus Monitor Tool Src Column
Referenced by:


Check Transmission Communication

Verify transmission communications are available on the J1939 communication link
1. Start the engine

5. Open the J1939 Bus Monitor via the EMPower Connect service tool menu option of ‘Tools-
>CAN Bus Monitor’
6. Verify that messages are being displayed in the J1939 Bus Monitor window indicating proper
connection of the tool to the J1939 data link
7. Examine the ‘Src’ column for a value of 03 which is the J1939 recommended source address
for a transmission
Result Diagnosis
03 exists within the ‘Src’ column of the J1939 Bus Monitor Pass
CAN Bus Monitor Tool Src Column
Referenced by:


Check Engine ECU Coolant Measurement

Verify the coolant temperature reported by the engine using engine manufacturer specified
troubleshooting procedures.
Result Diagnosis
Coolant temperature reported by the engine is OK Pass
Referenced by:

Check Transmission Cooling Request

Check the value of the transmission cooling request.
1. Start the engine

Trans % Fan Rqst within the J1939 Data area.
Result Diagnosis
=0 Zero
All other conditions Non-Zero
Dash Display
Trans % Fan
Request
Referenced by:

Determine Coolant Sensor Used

Determine which coolant sensor is being used by the software for fan control.
1. Start the engine

5. Using the F5--Cal display of the EMPower Connect service tool software, examine the
parameter called ‘Coolant Control To J1939’.
Result Diagnosis
‘Coolant Control To J1939’ = 0 Cooling System Sensor
All other conditions Engine Sensor
F5 - Cal
Coolant
Control to
J1939
Opening Diagnostics
Display
Referenced by:


Determine Intake Air Sensor Used
Determine which intake air sensor is being used by the software for fan control.
1. Start the engine

parameter called ‘Intake Air Control To J1939’.
Result Diagnosis
‘Intake Air Control To J1939’ = 0 Cooling System Sensor
All other conditions Engine Sensor
F5 - Cal
Intake Air
Control
to J1939
Opening Diagnostics
Display
Referenced by:

Determine If Transmission Fan Command Is Enabled

Determine if the software is expecting and will respond to a fan speed command from the
transmission.
1. Start the engine

parameter called ‘Trans Cooling Request Enable’.
Result Diagnosis
‘Trans Cooling Request Enable’ = 0 Disabled
All other conditions Enabled
F5 - Cal
Trans
Cooling
Request
Enable
Opening Diagnostics
Display
Referenced by:

Determine If Engine Shutdown Is Required

Determine if the software requires the engine to shutdown before the cooling system will be allowed
to shut down.
1. Start the engine

parameter called ‘Engine Shutdown Rqd. To Power Down’.
Result Diagnosis
‘Engine Shutdown Rqd. To Power Down’ = 0 No
All other conditions Yes
F5 - Cal
Engine
Shutdown
Rqd
Opening Diagnostics
Display
Referenced by:

Determine If Engine Communication Is Required
Determine if the software requires engine communications.
1. Start the engine

parameter called ‘Engine Communication Required’.
Result Diagnosis
‘Engine Communication Required’ = 0 No
All other conditions Yes
F5 - Cal
Engine
Comm
Required
Opening Diagnostics
Display
Referenced by:

Determine If J1939 Fan Reversal Was Commanded

Determine if a J1939 request for fan reversal occurred.
This determination will be vehicle manufacturer dependent. Consult the vehicle manufacturer to
determine if an automatically commanded fan reversal option was included within your installation.
Result Diagnosis
Automatic fan reversal commanded by vehicle controls Yes
All other conditions No
Referenced by:
Verify Fan Is Not Obstructed

Verify that the fan is not obstructed from spinning.
Inspect the fan as follows:
1. Verify that the fan rotation is free of debris, ice, or other objects that may prevent motion
Result Diagnosis
Nothing is preventing motion of the fan Pass
Referenced by:

Check Fault Status Information
Interpret the fault status information for a specific fault code.
1. Start the engine

communication between the EMPower Connect service tool software and the cooling
system.
5. Using the F4--Diag display of the EMPower Connect service tool software, examine
the number of fault counts for a specific fault code, the recent time of a specific fault code
which indicates the time at which the fault code most recently occurred, and the duration of
the fault code with indicates the cumulative duration of all occurrences of a fault code
Result Diagnosis
User judgment that there may be an intermittent Possible Issue
or recurring issue causing a specific fault code
User judgment that there is no concern regarding No Concern
a specific fault code
F4 - Diag
Diagnostics Display
Referenced by:

Diagnostic Procedures

Service Manual - TMC FiL-11 MH8-5031-504-4336

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Mini-HybridTM TMC/FiL-11 MH8–5031/5034/4336

Part Serial Number

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8

2701 North 30th Street

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 2

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 3

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 4

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 5

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 6

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 7

Service Technician Responsibilities

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 8

Product Safety Warnings

Make sure the work area is ventilated and well lit.

Make sure charged fire extinguishers are in the work area.

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 9

FiL-1 Fan # Resistor Value (Ohms)

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 10

Figure 2 - 5031/5034 TMC and FiL-11 Fans

Figure 3 – 4336 TMC and FiL-11 Fans

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 11

CAN Bus Interface Cable

Ignition Cable Assembly

Fan Reversal Push button and Diagnostic LED

Figure 4 - Push Button/LED

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 12

XX-YY where: XX is the first number of the fault code

The blink codes are read out in the following manner:

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 13

Figure 5 – TMC/FiL-11 5031/5034Edge Clip Locations

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 14

Figure 6 - TMC/FiL-11 4336 Edge Clip Locations

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REPLACEMENT NOTE: Pre-coat the last few threads of the (4)

FiL-11 Fan Install the mounting bolts and torque to 106±10

Figure 7 – FiL-11 Fan

WARNING: To avoid serious personal injury,

Disconnect the fan’s connector from the kit wire

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Figure 8 – Coolant Thermistor Figure 9 – CAC Thermistor

9980039008 Rev B -2010-07-16 © 2010 EMP TMC/FiL11 MH8 18

Figure 10 – TMC/FiL-11 5031/5034 Radiator Thermistor

Figure 11 – TMC/FiL-11 4336 Radiator Thermistor

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CAC Thermistor On Outlet Of

Figure 12 - CAC Thermistor Location

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Figure 13 - TMC/FiL-11 5031/5034 Harness layout

Figure 14 – TMC/FiL-11 4336 Harness layout

Connect the 7 pin Delphi connector at each FiL-

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Power/Ground Pass through Studs

WARNING: To avoid serious personal injury,

Figure 16 - 4336 Power Stud Assembly

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WARNING: To avoid serious personal injury,

NOTE: Each fuse assembly contains three fuses.

Figure 19 - 4336 fuse Location

Figure 17 - 5031/5034 Fuse location

Figure 20 - 4336 Fuse Assignment

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