esw group released december 07 thermacat on-road active

ThermaCat™ Installation Guide

SB-TF-068 Rev 03 - California School Bus of 28

ESW GROUP Released December 07th, 2011

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ThermaCat On-Road Active Level III System

Installation Guide

Number: SB-TF-068 Rev. 03

School Bus Horizontal Mounting

ON-ROAD KIT 1996-2004 Thomas Rear Engine

School Bus Equipped w/Cummins ISB 5.9/ISC 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 1996-2004Thomas Rear Engine School Bus equipped with a Cummins ISB 5.9/ISC 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) Remove the OEM muffler, tailpipe and hanger system. See Fig. 3.

Fig. 1 Fig. 2

2) Fig. 3 Fig. 4

shows the upper section of the OEM mounting brackets that are to be removed and be replaced by the ThermaCat™ mounting system.

Fig. 3 Fig. 4





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3) Remove the OEM mounts mounting bracket and heat shield.

4) Mount the two Relocating Brackets to the frame in original location of the OEM

mounting system using the OEM bolts. It may be necessary to trim the A/C bracket as indicated by the white line. See Fig. 5 Fig. 6.

Fig. 5 Fig. 6

5) Tighten the Upper Saddle Brackets until the Shock Absorber is has been

compressed to ½”- ¾”. See Fig. 7 Fig. 8

Fig. 7 Fig. 8

6) 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.





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7) The Hanger Saddle will be located on the inlet section at the front and the DPF section at the rear. Position the ThermaCat™ muffler so that the outlet end of the muffler is located 12” from rear upper saddle mount as in Fig. 9 Fig. 10.

Fig. 9 Fig. 10

8) Temporarily install the inlet pipe into the inlet of the ThermaCat™ muffler. Select

a straight section of pipe to install the Injector Nozzle Assembly that will allow the installation of the 4” Injector Band clamp. Mark the location at the top of the pipe so that the injector will installed at the 12 o’clock position. Remove the inlet pipe and drill a ¾” hole in the pipe. See Fig. 11 Fig. 12.

9) Install the inlet pipe into ThermaCat muffler and connect it to outlet pipe from the

turbocharger. Secure the inlet pipe with band clamps. See Fig. 11 Fig. 12.

Fig. 11 Fig. 12

10) 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





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Assembly on the ¾” hole that was drilled in the inlet pipe. 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. 15 Fig. 16.

Fig. 14

Fig. 15 Fig. 16

11) Install the tail pipe assembly. Install a short 90° swedged elbow into the

ThermaCat outlet pipe. Install a long 90° non- swedged elbow into the short 90° elbow at one end and through the hole in the bumper at the other end. Trim the rear section of the rear elbow so that it is flush with the outer surface of the rear bumper. See Fig. 15 Fig. 16.

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

fasteners to specification securing the muffler into position.

13) Install and tighten the band clamps on each of the pipe joints in the system between the turbo outlet pipe and the ThermaCat™ inlet pipe.

Fig. 13





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14) Install and tighten the band clamps on each of the pipe joints in the system between the ThermaCat™ exhaust outlet and the bumper.

15) The ECU Control Box mounting bracket is to be mounted on the flat metal surface in Fig. 17 Fig. 18. Temporarily mount the ECU Control Box to the ECU Box Mounting Bracket and position it so that the door will open without interference as in Fig. 17 Fig. 18. Close the door and mark the ECU Box Mounting Bracket location on the metal panel.

Fig. 17 Fig. 18

16) Remove the ECU Control Box from the ECU Mounting Bracket. Reposition the

ECU Mounting Bracket into the previously marked position. Transfer the location of the 3 holes in the Mounting Bracket on to the flat metal surface.

17) Fasten the ECU Mounting Bracket into position using 3/8” bolts. See Fig. 19

Fig. 20

Fig. 19 Fig. 20





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

Fig. 19 Fig. 20.

Fig. 21 Fig. 22

19) Install the Backpressure Hose (Ref. # 7/Fig. 57). 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.

20) 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. 23 illustrates a typical fuel reservoir. It is to be mounted on the lower frame rail secured with set screws and jamb nuts.





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Fig. 23

21) Install the Fuel Reservoir on 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 directly adjacent to the pinion flange of the rear axle housing. See Fig. 24 Fig. 25.

Fig. 24 Fig. 25

22) 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.

23) Connect the rear section of OEM fuel line to the reservoir via the compression fitting (supplied) installed in the NPT port at the top rear of the reservoir.

24) 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 fuel line to the compression fitting (supplied) installed in the outlet of the fuel shut off valve.





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Fig. 26 Fig. 27 Fig. 28

25) 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 43-50, the Shut off valve lever is placed in the open position again and then removed. See Fig. 26 Fig. 27 Fig. 28

26) Connect the fuel supply line (Ref. # 8/Fig. 57) to the upper NPT port in the

bulkhead of the ECU box (See Fig. 29 Fig. 30) at one end and the lower NPT port on the fuel reservoir at the other end as illustrated in Fig. 31 Fig. 32. It is acceptable to use either an angled or straight NPT fitting (supplied) in the reservoir to connect the fuel supply hose.

27) Install one end of the braided steel Fuel Injection Line (Ref. #2/Fig. 58) to the JIC

fitting located at the bulkhead on the ECU Control Box. See Fig. 29 Fig. 30. 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. 29 Fig. 30.

Fig. 29 Fig. 30

28) Install the T1 thermocouple into one of the NPT ports in the Inlet section of the

ThermaCat™ muffler. Install the T2 thermocouple into the NPT port located at the outlet section of the DOC section of the ThermaCat™ muffler. Install the T1 & T2 thermocouple until they bottom out. Pull the T2 thermocouple back 2” and tighten the compression nut. Both T1 & T2 should have approximately 2” exposed outside of the compression fitting.





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29) 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.See Fig. 31 Fig. 32.

Fig. 31 Fig. 32

ThermaCat System Wiring Diagram





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Fig. 33

- 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/3 Amp Fuse protection)

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

3 Amp Fuse





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Fig. 34

30) 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.

Fig. 35 Fig. 36





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31) 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. 35 Fig. 36, Fig. 37 Fig. 38.

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

battery. See Fig. 35 Fig. 36.

Fig. 37 Fig. 38

33) Secure the inertia switch inside the battery box on the wall towards the rear of

the bus. Ensure that the inertia switch is mounted level with reset button at the top as illustrated in Fig. 37 Fig. 38.

34) 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. See Wiring Diagram Fig. 33.

35) 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 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.

36) Secure the thermocouple wires and backpressure hose with P-clamps , tie straps or other suitable method.





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Fig. 39

37) 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. 39.

38) 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. 40 Fig. 41.

Fig. 40 Fig. 41

39) 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. 40 Fig. 41). 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. 34.





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40) 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. 42 Fig. 43 Fig. 44

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

ThermaCat™ ECU Commissioning Instructions

41) 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. 45.





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Fig. 45

Purging Fuel Lines

42) 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. 46Fig. 47 Fig. 48.

Fig. 46 Fig. 47 Fig. 48

43) 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. 49 Fig. 50 Fig. 51.





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Fig. 49 Fig. 50 Fig. 51

44) 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. 26 Fig. 27 Fig. 28) 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.

45) 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. 52).





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Fig. 52

46) 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.

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

Nozzle Housing previously mounted on the inlet pipe. See Fig. 53.

Fig. 53

48) 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.





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ThermaCat Mounting System Exploded Drawing

Fig. 54

Item # Number Description Qty

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

2 See Fig. 55 Upper and Lower Mounting Saddle 2

3 See Fig. 55 Relocating Bracket w/Heat Shield Ass. 1





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ThermaCat Mounting System Exploded Drawing Mounting System Part # 01001521

Fig. 55

Item Number Description Qty

1 101653 RELOCATING BRACKET, WELDMENT 2

2 101342 HEAT SHIELD PLATE, BLUE BIRD REAR ENGINE 2

3 101650 MOUNTING BRACKET 4

4 101656 HEAT SHIELD 1

5 R006-0003-0027 3/8 Nom Dia x 47/64 OD x .05THK Flat Washer 16

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

7 R006-0001-0012 3/8-16UNC x 1-1/4" LG HHCS (18-8 S/S) 8

8 R006-0003-0029 17/64"ID X 5/8"OD X 0.05" THK FLAT WASHER, ALLOY 20 SS 4

9 R006-0003-0026 1/4-20 UNC X 7/8" LG HEX HEAD CAP SCREW, 18-8 SS 4

10 R006-0001-0074 1/4-20 UNC X 7/8" LG HEX HEAD CAP SCREW, 18-8 SS 4

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





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ThermaCat Mounting System Exploded Drawing Mounting System Part # 02001248

Fig. 56


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 Sz, .385" ID, .680" OD, .094" min Thick 4

6 R006-0003-0027 3/8 Nom Dia 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” Lock washer 4





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ThermaCat Fuel and Electrical System Exploded Drawing

Fig. 57


1 R006-0001-0068 (2) 3/8” X 2” Bolt & Lock washer 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 00102147 1/4” ID x 30” Backpressure Hose w/fittings 1

8 00102152 1/4” ID x 60” 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 00101182 ECU Control Box Mounting Bracket 1

13 9100121 25’ Wiring Harness Extensions 2





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ThermaCat Diesel Fuel Injection Nozzle Assembly Exploded Drawing

Fig. 58


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. 59

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

49) 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. 60

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esw group released december 07 thermacat on-road active

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