EMP Cooling System Alternator Pump Maintenance Information September

EMP Cooling System, Alternator & Pump Maintenance Information September 2019 EMP PROPRIETARY INFORMATION: By accepting and retaining this document, you agree that the information contained hereon is proprietary to Engineered Machined Products, Inc. and constitute protectable trade secrets. You therefore agree to secure the documents, and secure the information they contain using it only for internal use.

Where is the Industry going? • Smarter systems and components Self diagnosing Re-programmable Communicate with each other Compatible with telematics including remote diagnostics • More electrification of vehicles and accessories Full electric vehicles have many electrically controlled pumps and fans • Higher voltage components (more efficient) • Smaller vehicles will start offering options • EMP is supporting all of the above

Florida Systems in Operation Star Metro JTA Gainesville Daytona Hernando USF PSTA HART Lynx Orlando Airport Theme Parks Citrus Sarasota LEE Palm Broward MDT 3

Mini-Hybrid™ Evolution: Gen I to Gen IV FL EMP Kits Covers All Systems Gen IV Gen III s& t n me e v ro p s Im Gen II Gen I (2006) C u o u in ont ost C ed s a cre e D

EMP TRANSIT • Improved cooling system control (new) • Programmable fan reversibility (enhanced) • Telematics compatibility (enhanced) • Robust bar and plate heat exchangers w/metal end tanks • Easy to remove heat exchangers • Extremely long life fans • Improved corrosion protection (enhanced) • Improved user friendly diagnostic software with histogram (enhanced)

EMP Designs, Programs, Tests & Mfgs Own Controllers, Fans, Etc. – Allows for seamless and rapid improvements Made in the USA

EMP SYSTEM SIMPLICITY TMC with EMPredict® & EMPrecision® technology Heavy duty, long life, aluminum brushless Fi. L-15 Fans w/built-in fuses All aluminum bar/plate Heat Exchanger Powder coated door seals One piece welded steel shroud assembly with patented baffle system Simplified water proof harness (no resistors)

DIAGNOSTICS CAPABILITIES • No-cost software tools for analysis • Integrated troubleshooting manuals • Vehicle/Engine/Cooling system data logging with histogram analysis • Works with INLINE 5/6/7, NEXIQ, & more • On-vehicle integration with telematics • PC and mobile based service tools

Diagnostics – Analysis (Real World Example) MH 8, Cummins Diesel, Passive Transmission, regulates to engine reported temperatures on J 1939 Data indicates this cooling circuit is not functioning correctly (EMP cooling system is functioning properly & responding to high temp commands) High coolant temperatures are occurring AND fan speeds are commanded to their maximum value of 5500 rpm Conclusion: High fan speeds are unable to cool effectively Recommendation: check items related to poor radiator coolant flow, poor radiator air flow, or unexpected heat sources Some suggested checks would include: thermostat, coolant pump, coolant level, radiator, transmission torque converter, etc.

TECHNOLOGY: • Gathers engine & temperature data in real time 2150 2200 2110 • Runs data through a proprietary algorithm (J 1939) • Anticipates cooling needs 2080 EMP Software • Reduces temperature spikes 2050 • Patent pending software designed In-house • Commands EMPrecision in exact cooling needed • Lowers current consumption & fan noise 1960 1990

Step Control EMP proprietary software Allows precise control of different diameter fans or components in the system Individual fan control vs outdated ‘bank’ control Allows for faster cab warm-up times Controls heat exchanger fluid temp without over-cooling Maintains engine/transmission optimum temperatures Baffles Patented baffle design prevents fan to fan recirculation Improves engine/transmission startup in cold conditions

Predictive Control Reactive Control kph Predictive Control °C °C Temp Control Tighter temp control, reduced overshoots and undershoots during Benefits to Cooling System • Lower current consumption • Increase fan life- less spikes • Lower fan noise levels • Smart enough to learn & anticipate conditions Benefits to Engine • Less thermal cycles=less metal fatigue • Increase life of: Pistons, Rings & Cylinder liners • Stable coolant temps=Longer coolant life • Possibly increase time between engine rebuilds

Cooling System Maintenance Recommendations

Data Link Adapters MINI-HYBRID™ Systems require an RP 1210 DLA compliant link Interface between PC and Vehicle Supported Adapters Nexiq USB-Link™ Cummins Inline 6 & 7 DG Technologies DPA 4+ Noregon DLA+Pro 2. 0 Download latest firmware and drivers from vendor website !!!!

Roadeo Training Module The EMP system is part of the national APTA ROADEO There are 6 fault conditions that need to be discovered for each module plus troubleshooting a “no start” on the engine. Each component is given 2 fault conditions (engine, transmission, EMP). The EMP fault conditions range from communication faults to physical failure of components and faults vary from year to year. There is special software that limits fan default speeds for noise reduction. Some faults are induced by utilizing Engineering level access on the service tool. Faults are not to be corrected at anytime. The technician uses the service tool, locates the active fault code, writes the code, locates the troubleshooting guide and writes the definition of the fault code. This is done within a 10 minute time frame for the entire module.

POWER SERIES ALTERNATORS Can be ordered with any cooling system Longer life - Extended Ultra-Life Bearings Lower Noise – Audible and Electrical Remote mount regulator improves life Regulator options Low Temperature- Runs up to 47 C cooler Efficiency highest in market Potential cost savings Compatible with smart regulators Compatible with Litton pulley Rebuildable Most widely used in transit P 450 P 535

Alternators – P 450 & P 535 Typically used for 60 ft buses or extreme conditions

Extended Life Bearings • EMP has co-developed a new extended life bearing – Power 450’s were tested on the EMP Accelerated Life Test. • • • Testing began several years ago The last generation production bearings achieve 5, 000 hours on this test. The “extended life bearings” have surpassed 12, 000 hours and are still running. – Field Testing recently completed at: • • • NYCT Phoenix St. Louis

Power 450 Improved Features • Testing has confirmed, the EMP alternator’s run cooler – A back to back test showed the EMP stator surface temperature to be 47°F cooler than others – EMP has made significant changes to the alternator air inlet system to reduce alternator temperatures. – EMP has implemented a 4” air inlet to maximize the air cooling and worked with OEMs. EMP Alternators are Electrically and Dynamically Balanced; run quieter. The EMP alternators runs smooth with very little vibration. Both the rotor and fan are dynamically balanced. Bench testing confirms the EMP alternators are very smooth and quiet. Noise testing results show a significant decrease in audible noise The ground isolated, noise suppression alternator reduced the electrical noise on the engine ground circuit by 10 X.

Alternator Maintenance Recommendation Every ~3. 5 years with new bearings

Support – – – Website-manuals, RMA, drawings Dealer & Service Network Regional Area Manager Regional Project Service Manager Onsite Training included; contact Steven Babin RSPM – Online Training available – Diagnostic Software Free to download – Warranty Support (can process through Gillig, NFI or ESS)

Setup Account Click on “Customer Login” Fill out information with asterisk next to it. Then “Register Account”

Download Latest Service Software Click on “Drivers and Downloads” Click on “EMP Service Suite” Click on “Download File”

ELECTRIC WATER PUMPS • Designed initially for Ag and Construction • High efficiency with variable flow • High power for such a small package • Long life brushless DC motor similar to fan technology • Heater pump and hybrid cooling in transit WP 29

Fill Procedure – Avoid Dry Run

EMP Contacts Regional Service Manager Steven Babin • Steven. Babin@emp-corp. com • 678 -468 -2727 • 906 -789 -7497 x 333 Regional Sales Manager David Allen • David. Allen@emp-corp. com • 906 -280 -4370 Customer Service Assistant Kaylyn Bosilovatz • Kaylyn. Bosilovatz@emp-corp. com • 906 -789 -7497 E-Mail – Customer/Technical Service Inquiries • Service@emp-corp. com – Warranty • Warranty@emp-corp. com – PO Submissions and Inquiries • escadvpos@emp-corp. com Phone – 906 -789 -7497 • Staffed 8 a. m. – 5 p. m. • on normal business days