ThermaCatTM On-Road Active Level III System

ThermaCat™ Installation Guide

SB-TF-061 Rev 01 - California School Bus Page 1 of 27

ESW GROUP Released December 07th, 2011

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ThermaCatTM

On-Road Active Level III System

Installation Guide

Number: SB-TF-061 Rev: 01

School Bus Horizontal Mounting

ON-ROAD KIT 1994-2000 Thomas Rear Engine

Saf-T-Liner School Bus Equipped w/Cummins ISC 5.9 or ISB 8.3 Engine





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Fuel & Backpressure Hose Specifications

All of the fuel supply hoses and the exhaust backpressure hose used in the ThermaCat™ system meet SAE 30R7 fuel line specifications. Use only OEM Lines or its equivalent

Fastener Specifications

All of the fasteners in the ThermaCat™ Installation Kit must be Grade 5 or higher. Where OEM fasteners must be removed and reinstalled, consult OEM manufacturer’s specifications for the correct assembly methods and follow torque table values.

Important Notes

All pictures and illustrations used in this manual are provided as reference for representational purposes only. Actual installation could be different.

ThermaCat™ is hung on isolators in an attempt to freely move to absorb the vehicle shocks. Hence, OEM exhaust brackets, interfering with these movements are not to be re-used.

Ensure that the Backpressure & fuel hoses have no valleys or loops in the hose that could trap condensation in the hose





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Torque Table

The suggested tightening torques provides an excellent starting point for determining torque requirements. Remember, you may need to vary these numbers somewhat based on the individual joint or the amount of fastener lubrication. This table is offered as the suggested maximum torque values for threaded products and it is hence only a guide.

Bolt Size Torque (in.lbs)

2-56 2.5

4-40 5.2

4-48 6.6

6-32 9.6

6-40 12.1

8-32 19.8

8-36 22

10-24 22.8

10-32 31.7

1/4" - 20 75.2

1/4" - 28 94

5/16" - 18 132

5/16" - 24 142

3/8" - 16 236

3-8" - 24 259

7/16" - 14 376

7/16" - 20 400

1/2" - 13 517

1/2" - 20 541

9/16" - 12 682

9/16" - 18 752

5/8" - 11 1110

5/8" - 18 1244

3/4" - 10 1530

3/4" - 16 1490

7/8" - 9 2328

7/8" - 14 2318

1" - 8 3440

1"- 14 3110





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INTRODUCTION This Installation guide has been prepared specifically for the installation of the ThermaCat™ Active Level III Diesel Particulate Filter on a 1994-2000 Thomas Rear Engine Saf-T-Liner School Bus equipped with a Cummins ISC 5.9 or ISB 8.3 engine For a complete functional description and service instructions for the ThermaCat™ device see:

ThermaCat™ Installation Instructions S501 Rev. 1 – Oct. 2009

INSTALLATION GUIDE

1) Raise and secure the left rear access door in the open position. Alternatively,

you can remove the door and put it safely aside during the installation process.

2) Remove the left lower body side panel to allow access to the OEM muffler

system for easier removal. See Fig. 2.

Fig. 1 Fig. 2

3) Figure 3 shows a view of the underside of the bus chassis with the OEM

muffler and hanger system removed. Remove the OEM muffler, inlet pipe, 4) tail pipe, hanger system and hardware. See Fig. 4.

5) Locate and remove the angle brackets on the front and rear mounting

brackets. See Fig. 6. Position the 2”x2”X13” angle brackets (not supplied) on the outside of the frame mounted support brackets as in Fig. 7 & 8.





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6) Mount the upper half of the muffler hanger saddle on both the front and rear

hanger brackets. Tighten the Upper Saddle Brackets until the lower Shock Absorber is has been compressed to ½”-¾”. See Fig. 9.

Fig. 3 Fig. 4

Fig. 5 Fig. 6

7) Raise the ThermaCat™ muffler up into the position in the upper half of the

hanger saddles. Install the lower section of the Muffler Hanger Saddles to secure the ThermaCat™ muffler. Do not tighten the lower saddle fasteners at this time.

8) Looking at the inlet of the ThermaCat™ muffler from the front, rotate the

entire muffler so that the inlet pipe is positioned in roughly the 11 o’clock position. See Fig. 10.





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Fig. 7 Fig. 8

Fig. 9 Fig. 10

9) Install a bellows on to the outlet pipe from the turbo as in Fig. 12.

10) Install a long 45° non swedged elbow into the ThermaCat™ inlet pipe. Install

a short 90° elbow (swedged) between the bellows and the long 45° elbow. See Fig. 11 & 13.

Fig. 11 Fig. 12





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Fig. 13 Fig. 14

11) Select a point on between the bellows and the ThermaCat™ muffler to install

the Injector Assembly. Drill a ¾” hole in the inlet pipe for the Fuel Injector assembly. This point must be between 9”-24” away from the ThermaCat™ muffler inlet. The further away from the muffler inlet that the injector is located the better. Ensure that the hole is placed in a position that will allow the entire band clamp to be located on a straight section of pipe. See Fig. 14.

Fig. 15 Fig. 16

12) Install the tail pipe assembly. Install 2 short 45° swedged elbows together to

form a tail pipe assembly that will bring the exhaust outlet out through the hole in the rear bumper. Trim 1”-2” from the rear section of the rear elbow so that it is flush with the outer surface of the rear bumper. See Fig. 16.

13) After positioning all of the inlet and tail pipes, tighten the mounting saddle

fasteners to specification securing the muffler into position.





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Fig. 17 Fig. 18

14) Install band clamps on each of the 4 pipe joints in the system between the

turbo outlet pipe and the ThermaCat™ inlet pipe. See Fig. 12, 13 &17.

15) Install band clamps on the 2 pipe joints in the tail pipe connections exiting the ThermaCat™ muffler. See Fig. 18.

Fig. 19 Fig. 20 Fig. 21

16) Apply a thin layer of Ultracopper™ to both sides of the Injector Assembly

Gasket and place it on the curved mating surface of the injector assembly. Ensure that no gasket sealer can interfere with the injector spray pattern. Place the Injector Assembly on the ¾” hole that was drilled in the inlet pipe between the bellows and ThermaCat™ muffler. Install the Injector Assembly Band Clamp securing the Fuel Injector Assembly to the inlet pipe. Tighten the clamp until the clamp conforms to the injector body for a positive seal. See Fig. 21.





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ECU Control Box Mounting Location – Option A

17) Remove the 3 fasteners indicated directly behind the air filter assembly. Position the ECU mounting bracket and re-install the 3 bolts. See Fig. 22.

18) Mount the ECU Control Box on to the ECU Control Box Mounting Bracket.

See Fig. 23.

ECU Control Box Mounting Location – Option B

19) Mount the ECU Control Box T-Bracket to the bulkhead above the engine as in Fig. 24.

20) Mount the ECU Control Box on to the ECU Control Box Mounting Bracket.

See Fig. 25.

Fig. 22 Fig. 23

Fig. 24 Fig. 25





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Fig. 26 Fig. 27

21) Install the Backpressure Hose (Ref. # 7/Fig. 63). Connect one end of the

hose to the lower bulkhead NPT port on the ECU Control Box. Route the hose towards the front of the ThermaCat™ muffler system. Connect the remaining end of the Backpressure Hose to one of the NPT ports on the upper half of the Inlet/DOC section of the ThermaCat™ muffler. The use of angle adapters to connect the Backpressure Hose is optional to ensure that condensation can properly drain back into the ThermaCat™ muffler. Ensure that the Backpressure hose has no valleys or loops in the hose that could trap condensation in the hose thereby preventing an accurate exhaust backpressure input signal to the ECU.

22) The fuel supply for the ThermaCat™ active regeneration cycle comes from

the fuel reservoir which is connected into the OEM fuel return line to the fuel tank. Fig. 28 illustrates a typical fuel reservoir. It is to be mounted on the lower frame rail secured with set screws and jamb nuts. There are two options for the location of the Reservoir. If the frame rail in the area indicated in Option “A” is double thickness, the Reservoir will be mounted as indicated in Option “B”.





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Fig. 28

Reservoir Mounting Option “A“

23) Install the Fuel Reservoir on the inside of the left side of the bus frame. Back out the set screws and lock nuts and slide the reservoir on the lower inside flange section of the frame rail 7” – 10” forward of the front side of the rear axle. Take the measurement from the rear axle directly below the frame rail. See Fig. 29 & 30.

Fig. 29 Fig. 30 Fig. 31

Reservoir Mounting Option “B“

24) Install the Fuel Reservoir on the inside of the right side of the bus frame.

Back out the set screws and lock nuts and slide the reservoir on the lower inside flange section of the frame rail above the rear axle 18” – 21” rearward of the mid-chassis cross member. See Fig 31.

25) Locate the return line in the OEM fuel injection system between the engine

and the fuel tank. Remove 2” – 6” of the return line adjacent to the fuel reservoir.





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Fig. 32 Fig. 33

26) Connect the rear section of OEM fuel line to the reservoir via the

compression fitting installed in the NPT port at the top rear of the reservoir. See Fig. 32.

27) The fuel shut off valve is installed in the top front NPT port of the reservoir between the fuel reservoir and the fuel tank.. Connect the remaining section of OEM return fuel line to the compression fitting (supplied) installed in the outlet of the fuel shut off valve. See Fig. 33

Fig. 34 Fig. 35 Fig. 36

28) The Fuel Shut off Valve is placed in the off position only while bleeding the

air from the fuel supply hose to the ECU. Once the system is bled during the commissioning process as described in paragraph #’s 47-53, the Shut off valve lever is placed in the open position again and then removed. See Figs. 34-36.

29) Connect the fuel supply line (Ref. # 8/Fig. 64) to the upper NPT port in the

bulkhead of the ECU box (See Fig. 37) at one end and the lower NPT port on the fuel reservoir at the other end as illustrated in Fig. 31. It is acceptable to use either an angled or straight NPT fitting (supplied) in the reservoir to connect the fuel supply hose.

30) Install one end of the braided steel Fuel Injection Line (Ref. #2/Fig. 65) to the

JIC fitting located at the bulkhead on the ECU Control Box. See Fig. 36.





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Connect the other end of the braided hose to the Fuel Injector Assembly mounted on the inlet pipe. A 90° fitting is supplied as an option to be used at either end of the braided steel Fuel Injection line. See Fig. 38.

Fig. 37 Fig. 38

31) Install the T1 thermocouple into one of the NPT ports in the Inlet/DOC section of the ThermaCat™ muffler. Install the T2 thermocouple into the angled NPT port located just prior to the DPF section of the ThermaCat™ muffler. Install the T2 thermocouple until it contacts the front face of the DPF inside the ThermaCat muffler. Pull the T2 thermocouple back 2” and tighten the compression nut. Both T1 & T2 should have approximately 2” exposed outside of the compression fitting.

32) Connect the black shielded wire to the T1 thermocouple. Connect the red

shielded wire to the T2 thermocouple. The thermocouples can be bent with a radius for clearance purposes.

Fig. 39 Fig. 40





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ThermaCat System Wiring Diagram

Fig. 41

- White (thick – 18Ga. or 1.0 mm²) Battery Plus (+) (with 7.5Amp Fuse protection)

- Brown (thick – 18Ga. or 1.0 mm²) Battery Negative (-) (this has to be connected to the battery)

- White (thin – 22Ga. or 0.75 mm²) Key-on /Engine Off power source (+) (power must be off when

engine is not running) (w/3Amp Fuse protection)

3 Amp

Fuse





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ThermaCat™ Key-On/Engine-Off Circuit Wiring Diagram

Fig. 42

33) Route the 12v battery positive and negative wires from the ECU wiring

harness into the battery box through the existing grommeted hole with the main power and ground cables to the battery.





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Fig. 43 Fig. 44

34) The 12v power source to the ECU is connected in series to the fuse holder

(7.5A mini fuse-supplied) and inertia switch wire. This wire is connected to the positive battery terminal. See Fig. 43, 45 & 46.

35) The ground wire from the ECU is connected to the negative terminal of the

battery. See Fig. 44.

Fig. 45 Fig. 46

36) Secure the inertia switch inside the battery box on either the front, rear or

back wall to provide adequate battery clearance. Ensure that the inertia switch is mounted level with reset button at the top as illustrated in Fig. 46.

37) Install the Inertia Switch and Fuse Holder wires in series in the battery

positive circuit. Slide the battery tray in and out with the positive and negative wires positioned similar to the final installed position. Remove excess wire from both the positive and negative wires.

38) Install a ring terminal on the ends of the positive and negative wires. If

necessary, notch the protective plastic shields on the OEM positive and





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negative battery cable ends to accommodate the ThermaCat™ wiring terminals. Install the fused positive wire on the positive battery terminal of the battery. Install the negative wire on the ground battery terminal of the battery.

39) Route the shielded T1 & T2 thermocouple wires from the ECU Control Box to

the front of the ThermaCat™ muffler. Attach the T1 (black) wire to the thermocouple mounted at the front of the DOC. Attach the T2 (red) wire to the thermocouple mounted in the rear of the DOC. See Fig. 39.

40) Secure the thermocouple wires and backpressure hose with P-clamps or

other suitable method. See Fig. 40.

Fig. 47

41) The LED wires and the Key-on/Engine-off white wire are routed from the

ECU Control Box to the front of the engine compartment into and through the full length of the storage compartment under the seating area of the bus. See Fig. 47.

42) The wiring harness is then routed into the Power Distribution Panel located

on the left side of the bus directly below the driver’s side window adjacent to the driver’s instrument panel. See Fig. 48.

Fig. 48 Fig. 49





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43) The Key on/Engine off white wire is connected to the Copper Jumper Strip between the Body Relay and Fuse/Breaker Box #1 inside the Power Distribution Panel. (See Fig. 49). The Key on/Engine off circuit powers the data logging feature of the ThermaCat™ system. Current draw for this circuit is less than 30mA. Install a fuse holder with a 3 amp fuse (supplied) in series into the Key on/Engine off circuit as indicated in the wiring diagram. Fig. 42.

44) The LED is mounted on the instrument panel in the best possible line of sight

for the driver. The LED is “green” during normal operating conditions. If a fault in the system develops, the LED will turn “red” as a warning to driver that the ThermaCat™ system needs to be inspected by an authorized ESW dealer.

Fig. 50 Fig. 51 Fig. 52

Alarms / LED Display

Alarm type LED- Color

Back Pressure over pre-alarm level Yellow

Back pressure over alarm level Blinking Red

Thermocouple pre-DOC fault Blinking Red

Thermocouple post DOC fault Blinking Red

Customer service necessary Blinking Red





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ThermaCat™ ECU Commissioning Instructions

45) Make sure that the main wiring harness master connector is securely

plugged into the ECU inside the ThermaCat™ Control box. The connector snap lock must engage to ensure a proper connection and tight seal. See Fig. 53.

Fig. 53

Purging Fuel Lines

46) Remove the fuel injector nozzle assembly by removing the two Allen head bolts in the injector housing. Let the injector to hang down into the catch basin for fuel line air purging process. See Fig. 54-56.

Fig. 54 Fig. 55 Fig. 56

47) Remove the fuel supply hose from the hose barb connection on the bottom

of the ECU in the Control box. Position the loose hose end into a clear catch bottle to observe fuel flow. See Fig. 57 through 59.





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Fig. 57 Fig. 58 Fig. 59

48) Start the vehicle in a well ventilated area and run the engine at idle for one

(1) minute in order to begin filling the ThermaCat™ fuel reservoir and ECU supply line hose with diesel fuel.

Slowly close the shut-off valve (Fig. 35) located on the fuel tank (return) side of the ThermaCat™ reservoir unit causing the return fuel to fill reservoir and ECU supply line hose. Observe the free flowing fuel filling the fuel filter and running into the clear catch bottle. Pinch off the end of the supply line hose with needle nose pliers while simultaneously opening the shut-off valve. Reinstall the open end of the fuel hose back onto the ECU hose barb and tighten hose clamp. After purging the air from the fuel supply line to the ECU, open the shut-off valve and remove the shut-off valve lever from the shut off valve. 49) Plug in the USB/Serial cable into the ThermaCat™ ECU computer port

located in the top end of the ECU. Plug the USB end into the computer being used to commission the ThermaCat™ and fuel injector system. Turn the computer on and open the ThermaCat™ User Software. Set the COM port and press connect. Make sure the firmware version and serial number are displayed. (Light blue readings). (See Fig. 60).

Fig. 60





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50) Activate the ECU fuel pump using the “Pump Enable “feature in the ThermaCat™ activation software. The fuel pump will emit an audible ticking sound indicating that it is pumping. Observe the spray pattern and atomization of the fuel as the pulsing injector opens and closes with the cadence of the pump. Once the injector is producing a uniform atomized spray pattern, deactivate the ECU fuel pump with the computer software.

51) Re-install the fuel injector with the braided steel line still attached into the

Injector Nozzle Housing previously mounted on the inlet pipe.

Fig. 61

52) Restart the vehicle engine and visually inspect all the fittings, connections

and band clamps for fuel and exhaust leaks. Ensure that there are no loose wires or hoses that could come into contact with moving parts or hot surfaces on the vehicle prior to road test.

53) Re-install the body side panel and secure the left rear access door.





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ThermaCat Mounting System Exploded Drawing

Fig. 62

Item Number Description Qty

1 144-12-0-09-6333 ThermaCat DPF Muffler 4“ side inlet/4“center outlet 1

2 02001248 Upper and Lower Mounting Saddle 2

3 NA Relocating Bracket w/Heat Shield Ass. 1





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ThermaCat Mounting System Exploded Drawing Mounting System Part # 02001248

Fig. 63


1 2002015 144 MOUNTING STRIP, 11.25" DIA I.D. 1

2 R006-0001-0068 3/8-16 UNC 2.0" LG 1" LG THRD, HHCS 18-8 SS 4

3 R006-0002-0011 0.375-16 UNC FLEX TYPE LOCK NUT 2

4 R006-0002-0028 3/8"-16 Hex Nut, 9/16" W x 21/64" H, 316 SS 2

5 R006-0003-0010 18-8 Stainless Steel Spring Lock Washer 3/8" Screw Size, .385" ID, .680" OD, .094" min Thick 4

6 R006-0003-0027 3/8 Nom Diameter x 47/64 OD x .05THK Flat Washer 8

7 2001265 144 MOUNTING SADDLE 1

8 2001147 SNUBBING WASHER 4

9 2001016 SHOCK ABSORBER 2

10 R006-0002-0011 3/8-16 UNC Locknut 4

11 R006-0003-0010 3/8” Lockwasher 4





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ThermaCat Fuel and Electrical System Exploded Drawing

Fig. 64


1 R006-0001-0068 (2) 3/8” X 2” Bolt & Lockwasher 1

2 91001014 ECU Control Box Assembly 1

3 00102183 Inertia Switch / 7.5A Fuse and Holder 1

4 R008-0002-0040 Fuse Holder w/3A Fuse 1

5 R008-0001-0028 Thermocouple NPT/Compression Fitting x 2 2

6 91003004 Thermocouple 2

7 00102153 1/4” ID x 66” Backpressure Hose w/fittings 1

8 00102160 1/4” ID x 108” Fuel Supply Hose w/fittings 1

9 00102129 Fuel Reservoir w/shutoff valve 1

10 R008-001-0006 Driver's LED Display 1

11 R008-0001-0002 Wire Harness 1

12 00101160 ECU Control Box Mount-Bracket Option(A) 1

13 9100121 25’ Wiring Harness Extensions 2

14 00101157 ECU Control Box Mount-Bracket Option(B) 1





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ThermaCat Diesel Fuel Injection Nozzle Assembly Exploded Drawing

Fig. 65


1 R008-0001-0130 Fitting ¼”-18 NPT x 7/16” – 20 JIC 1

2 R008-0001-0151 3/16” ID. 5’ Braided Injector line – 2x1/4” JIC 1

3 00103052 MAF Band Clamp Assembly 4” Diameter 1

4 00102083 Injector Nozzle Assembly 1

5 Inlet Pipe – Not supplied





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ThermaCat™ ECU Enclosure Exploded Drawing

Fig. 66

ITEM # PART # DESCRIPTION QTY

1 91001069 ECU ENCLOSURE WITH FITTINGS, RIGHT DOOR 1

2 91001070 ECU/WATER SEPARATOR MOUNTED, RIGHT DOOR 1

3 91001076 316 SS 4mm DIA 0.5mm WALL TUBE ANNEALED, 9 7/8" LENGTH 1

4 R008-0001-0002 WIRE HARNESS (VENDOR P/N: 275961) 1

5 R006-0007-0002 CABLE TIE 12" 2

6 R006-0007-0002 CABLE TIE 12" 1

7 R008-0001-0136 CABLE TIE 4" 1

8 91001081 5/32" OD NYLON TUBE, 10" LENGTH 1


10 R008-0001-0182 FUEL FILTER 1

11 R006-0009-0011 Mini Hose Clamp, Galvanized Steel (Hansaflex # ASK 10-12M) 1

12 R006-0009-0012 Worm Drive Hose Clamp, Galvanized Steel (Hansaflex #ASK 12-20) 1

13 91001086 1/4" I.D. FUEL HOSE, SAE 30R7, 15" LENGTH 1

14 91001087 1/4" I.D. FUEL HOSE, SAE 30R7, 7" LENGTH 1






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ThermaCat™ Engine Tag Installation

54) Install the ThermaCat™ Serial number Tag into the engine compartment area by bolting it to the engine in a location visible to enforcement officials.

Fig. 67

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ThermaCatTM On-Road Active Level III System