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ThermaCat™ Installation Guide

SB-IC-041 - California School Bus Page 1 of 28

ESW GROUP Released November 22nd, 2011

– ADVANCED TECHNOLOGY FOR A CLEANER FUTURE –

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ThermaCatTM

On-Road Active Level III System

Installation Guide Number: SB-IC-041

School Bus Horizontal Mounting

ON-ROAD KIT

1993-2005 International School Bus Navistar 3800 Series Bus Chassis with Carpenter or Amtrans

Equipped w/T444E or DT466 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 1993-2005 International School Bus mounted on a Navistar 3800 Series Bus Chassis with Carpenter or Amtrans body equipped w/T444E or DT466 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 and mounting brackets from the vehicle as in Fig. 1.

Fig. 1

Fig. 2

2) Fig. 2 shows a rear view of the underside of the bus chassis with the OEM

muffler and hanger system removed.





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ThermaCat 02002050-Hanger System

Fig. 3

Fig. 4

Fig. 3 shows a typical school bus mounting bracket mounted to be mounted on the upper frame rail which requires no frame modifications for installation.

3) Remove the approximately 24”-26” from the front of the exhaust extension/tailpipe that will attach to the outlet of the ThermaCat™ system. The cut will be just after the 2nd bend in the pipe leaving only a straight section of pipe to attach to the outlet of the ThermaCat™ system.

4) The exact location of the Upper Frame Mounting Brackets will be determined by the available spacing between the body crossmembers and the final positioning of the 3 band clamps on the ThermaCat™ Muffler sections.

5) Position the Frame Mounting Brackets on the upper frame rail, (Fig. 5 & Fig.

6) between the under body crossmembers.

6) The front Mounting Bracket will be located directly behind the frame crossmember as indicated in Fig. 5. The second Mounting Bracket will be located approximately 12-16” rearward from the front Mounting Bracket, directly behind the frame crossmember as illustrated in Fig. 6. The rear Frame Mounting Bracket will be located in the first space between the underbody crossmembers rearward of the second frame mounting bracket as illustrated in Fig. 6.





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7) Leave the fasteners loose until the ThermaCat™ is raised into position to allow for final positioning of the muffler band clamps. Each upper frame mount will have up to 6” adjustment between the crossmembers.

Fig. 5

Fig. 6

8) Position the Mounting Bracket Band Clamps on the ThermaCat™. (See Fig.

9). The front clamp should be located on the DOC, the center clamp will be located on the DPF and the rear clamp will be located on the outlet section. Do not tighten fasteners on the clamps at this time.

9) Raise the ThermaCat™ into position and install the inlet on to the exhaust

inlet pipe from the turbo. Once the ThermaCat™ is installed on to the inlet pipe, install a 3.5” to 4” adapter pipe into the outlet tube of the ThermaCat system. Measure the distance between the ends of the exhaust extension/tail pipe to the pipe expansion outlet tube. Install a length of 4” OD exhaust pipe between the reducer and the exhaust extension/tail pipe. The outlet pipe extension length will be between 12”-16”. (See Fig. 7).

Fig. 7





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10) Raise the ThermaCat™ muffler approximately ¼ to ½ inches. Align the holes and secure the 3 band clamp/adjustable hanger bar assemblies to the 3 frame mounting brackets on the upper frame rail as in Fig. 8. The ThermaCat™ E020-M018-B hanger system is designed to allow for small adjustments in height by providing equally spaced holes on both the Frame Mounting Bracket and the Adjustable Hanger Bar. Install the mounting hardware according to the ThermaCat™ Mounting System Assembly Drawing (Fig. 45 & Fig. 46).

11) With the system still raised and supported, tighten all of the fasteners in the

hanger system. Begin with the Frame Mounting Brackets and then the Adjustable Hanger Bars. Lower the ThermaCat™ system so that the hanger system is supporting the weight of the entire system.

12) Position the individual band clamps as close to the center of the

ThermaCat™ section that each one is mounted on as illustrated in Fig. 9. For example, the band clamp mounted on the DOC should be relatively close to the center of the DOC. Use the same method to locate the band clamps on the DPF and Outlet section. There is some flexibility in these locations. This is relative to how far forward/rearward that you can adjust the Upper Frame Rail Mount between the Body Crossmember sections. Do not allow the Mounting Bracket Band Clamp to cover or in any way impede the ability to read the entire CARB Verification label on the DOC/DPF assembly. Once the system is secured, the linear distance from the tailstock flange of the transmission to the front face of the DOC section of the ThermaCat™ system will be between 28”-32”.

Fig. 8

Fig. 9





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13) Install and secure the inlet/outlet pipes to the ThermaCat™ system with band clamps.(Fig. 9)

14) The location of the ECU box must allow for the routing of the 5’- 4 mm

stainless steel injection line to the fuel injector which is mounted on the inlet pipe in front of the ThermaCat™ muffler.

ECU Box Mounting Location A (Standard)- Battery Box Mounting

15) Mount the ECU Box on the front outside surface of the battery box on the

left side of the bus (Fig. 10a).

16) Mount the ECU Box Lower Shield &ECU Control Box Assembly to the T-Mounting Bracket. Position the ECU Box/Mounting bracket assembly against the front outside surface of the battery box. Ensure the ECU box is mounted on a flat surface and the door opening is unobstructed. Using the T-bracket as a template mark and drill two ½” holes in the front side of the battery box. Install the T-bracket support plate on the inside of the battery box as in Fig. 11a with the threaded section of the (Grade 5 or above - 3/8”x1.25” UNC) bolts towards the outside of the battery box. Install the ECU Control Box/T-Mounting Bracket assembly to the battery box as shown in Fig. 10a.

Fig. 10a

Fig. 11a





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Fig. 10b Fig. 11b

ECU Box Mounting Location B (Optional)– Rail Frame Mounting:

17) Mount the ECU Control Box T-Bracket to the frame as per Fig. 10b and Fig. 11b

18) The fuel supply to the ECU and the exhaust backpressure enters the ECU box at the ECU Box bulkhead. The fuel supply line from the Fuel reservoir is attached to the top left NPT port in the bulkhead. (See Fig. 12).

19) The Backpressure hose is connected to the front of the DOC and on the

other end enters the bulkhead in the lower left NPT port.

20) The maximum 5’-4 mm stainless steel injection line connects to the ECU box at the bulkhead and is routed to the 90° elbow (optional) or directly to the injector nozzle mounted on the inlet pipe. (See Fig. 12 & Fig. 13).

Fig. 12

Fig. 13





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21) Drill a ¾” hole in the top of the exhaust inlet pipe between 8”-20” ahead of the muffler to accept the injector nozzle. Position the band clamp with the hole in it over the 5’-4 mm stainless steel line and temporarily wrap the band clamp loosely around the inlet tube with the injector located in the drilled hole. Route the 5’ injector line along the underside of the bus body across to the left side of the bus over the frame and down to the ECU bulkhead. At-tach the 4 mm-stainless steel injector line to the single compression fitting on the right side of the bulkhead of the ECU Box. (See Fig. 12)

Fig. 14

Fig. 15

22) Install the supplied backpressure hose (Ref. #21/Fig. 47) Connect one end

of the hose to the lower bulkhead NPT port on the ECU box. Route the hose up and over the frame rail, across the underside of the bus body over to the front of the DOC. Connect the other end of the hose to one of the NPT ports located at the upper/front of the DOC as in Fig. 14. The use of angle adapters to connect the backpressure hose to the ThermaCat™ system is optional to ensure that condensation can drain back into the ThermaCat™ system. Secure the injector hose to the underside of the bus body using “tie straps, P-clamps” or other suitable method to reduce vibration.

23) 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 tank. Fig. 15 illustrates a typical fuel reservoir. It is to be mounted on the upper frame rail secured with set screws and jamb nuts.





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24) The fuel reservoir is to be mounted on the inside of the upper frame rail on the right side of the frame. It should be positioned approximately 12”-15” forward of the Frame Crossmember that is located directly above the Inlet/DOC section of the ThermaCat™ system. (See Fig. 16). Back out the set-screws and jamb nuts and slide the reservoir slot over the upper frame rail in the location mentioned above.

Fig. 16

25) Locate the return fuel line to the fuel tank from the OEM Fuel Injection

system. Remove 2”-6” of the OEM fuel return line adjacent to the Fuel Reservoir.

26) Connect the front section of OEM fuel return line to the compression fitting (supplied with reservoir assembly) to the front of the reservoir. (See Fig. 17).

27) Connect the remaining rear section of OEM fuel return line connected to the fuel tank to the compression fitting (supplied with the reservoir assembly) to the shut-off valve at the rear of the fuel reservoir. (See Fig. 18).





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Fig. 19

28) The shut-off valve is connected in line between the fuel reservoir and the

fuel tank. It is placed in the off position (Fig. 20) 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 paragraphs #42-46, the shut off valve lever is to be placed in the open position (Fig. 18) and then removed. (See Fig. 21).

Fig. 20

Fig. 21

29) Connect the fuel supply line (ref. #22/Fig. 47) to the upper NPT port in the

ECU bulkhead at one end and the lower NPT port on the fuel reservoir at the other end as illustrated in Fig. 21. It is acceptable to use either an angled or straight NPT fitting (supplied) in the reservoir for the Fuel Supply Hose.

Fig. 17 Fig. 18





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30) Secure the Backpressure, Fuel Supply hose and braided stainless steel Fuel Injector Line with “tie straps”, P-clamps or other suitable method to reduce vibration. (See Fig. 22).

Fig. 22

ThermaCat System Wiring Diagram

Fig. 23

- 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)





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31) Route the 12v battery positive and negative wires from the ECU wiring harness into the battery box through the existing hole with the main power and ground cables to the battery.

Fig. 24

Fig. 25

32) 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. 24, Fig. 26 & Fig. 27).

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

battery. (See Fig. 25).

Fig. 26

Fig. 27

34) The inertia switch is secured inside the battery box on the wall towards the

rear of the bus with self tapping sheet metal screws. Ensure that the inertia switch is mounted level with reset button at the top as illustrated in Fig. 27.





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35) Install the Inertia Switch and Fuse Holder 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. Determine the appropriate length of wire that is required to achieve a clean installation. Remove excess wire from both the positive and negative wires.

36) Install a ring terminal on the ends of the positive and negative wires. Notch

the protective plastic shields on the OEM positive and negative battery cable ends (if required) 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.

37) Route the shielded T1 & T2 thermocouple wires up and over the frame

across to the ThermaCat™ DPF muffler. Attach the T1 (black) wire to the thermocouple mounted at the front of the DOC. (See Fig. 28). Attach the T2 (red) wire to the thermocouple mounted in the rear of the DOC.

Fig. 28

Fig. 29

38) The wiring harness from the ECU entering the engine compartment contains

both the Key-on/Engine/off wire and the LED harness.

39) The LED harness and the Key-on/Engine-off white wire pass through the firewall directly in front of the driver’s cockpit area. The hole is located adjacent to the main wiring harness for the body electrical and it enters into the back side of the driver’s compartment instrument control panel and the ignition switch. After the wires have been installed, seal the hole with a suitable waterproof sealant for protection. (See Fig. 29).

40) The Key-on/Engine-off power source to the ECU is connected to a blank

terminal on the ignition switch as indicated in Fig. 30.





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Fig. 30

41) The Key-on/Engine-off power source to the ECU is connected to a blank terminal on the ignition switch as indicated in Fig. 30

42) 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. (See Fig. 32 & Fig. 33).

Fig. 31

Fig. 32

Fig. 33

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





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Customer service necessary Blinking Red

ThermaCat™ ECU Commissioning Instructions

43) 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. Ensure that the connector is secure and cannot be removed. (See Fig. 34).

Fig. 34

44) 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. 35)





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Fig. 35





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Purging Fuel Lines

45) Remove the fuel injector assembly band clamp that was temporarily installed from the inlet pipe located between 8” - 20” in front of the ThermaCat™ muffler. Allow the unit to hang down into the catch basin for fuel line air purging process. (See Fig. 36& Fig. 37).

Fig. 36

Fig. 37

46) 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. 38 to Fig. 40).

Fig. 38

Fig. 39

Fig. 40

47) 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.





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48) Slowly close the shut-off valve (Fig. 41) located on the 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 and reinstall the open end back onto the ECU hose barb and retighten 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.

Fig. 41

49) Activate the ECU fuel pump using the setting 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.

50) Shut off the engine and let the inlet pipe cool down to a manageable

temperature. Apply an even coat of Permatex™ Ultra-Copper gasket sealer (Fig. 44) to both sides of the supplied flexible gasket. Position the gasket (Fig. 43) on the curved mating face of the fuel injection nozzle. Position the injection nozzle/band clamp assembly into the ¾ inch hole on the exhaust inlet pipe and tighten the band clamp. Ensure that no gasket sealer touches the injector nozzle or pin. Tighten the band clamp until the clamp conforms to the injector body ensuring a positive seal.





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Fig. 42

Fig. 44

51) 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.

Fig. 43





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ThermaCat Mounting System Exploded Drawing Part # 02002099

Fig. 45

Item # Number Description

1 144-12-0-09-5153 Ø10.5" x 12" DPF ThermaCat™ Offset Ø4" ID Inlet, Offset Ø4.0" ID Outlet

2 02002044 Ø11.25" Band Clamp

3 R006-0001-0032 Adjustable Hanger Bar Hardware 3/8-16UNC x 1 1/2" LG Hex Head Bolt

4 02002024 Hanger Shock Absorber

5 R006-0001-0036 Hanger Shock Absorber Hardware 1/2-13UNC x 2 1/2" LG Hex Head Bolt

6 02002030 Adjustment Plate and bracket Assembly

7 00102033 Plate/Spacer – Not required

8 00101616 Frame Rail Inner Hangar Clamp

9 R006-0001-0016 Frame Rail Mounting Hardware 3/8-16UNC x 1" LG SHSC

10 00102029 Frame Rail Upper Clamp

11 R006-0006-0037 / 0103052 Strap Clamp 4" OD





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Fig. 46

BOM ID # DESCRIPTION PART NUMBER QTY

2 Band Clamp – 11.25 dia. 02002044 1

2a 3/8”-16 UNC x 2.5” Bolt R006-001-0037 1

2b 3/8” spring lock washer R006-003-0010 2

2c 3/8” flat washer R006-003-0009 2

2d 3/8”-16 UNC hex lock-nut R006-002-0006 1

Fasteners in this sub-assembly should meet Grade 5 or above standards





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ThermaCat Fuel and Electrical System – Battery Box Mount

Fig. 47


12 91001015 ECU Box Assembly

13 00101157 ECU Box T-Mounting Bracket

14 R006-0002-0007 ECU Box Mounting Bracket Hardware Nylon Insert Locknut 3/8-16

15 00101172 T-Bracket Backing Plate

16 R006-0001-0016 ECU Box Frame Clamp Hardware 3/8-16UNC x 1" LG SHSC

17 0102036 ECU Box lower Shield

18 R008-0001-0002 Wire Harness

19 N/A N/A

20 N/A N/A

21 00102151 1/4” x 54” w/ #4-3/8” NTP fittings x 2 Backpressure Hose w/fittings

22 00102153 1/4” x 66” w/ #4-3/8” NTP fittings x 2 ECU-Fuel Supply Hose w/fittings

23 00102129 Fuel Reservoir w/shut off valve & fittings

24 00102183 Inertia Switch / 7.5A Fuse and Holder

26 91001020 Thermocouple x 2

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

28 R008-001-0006 Driver's LED Display





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ThermaCat Fuel and Electrical System – Frame Mount

Fig. 48

Item Number Description

1 91001015 ECU Box Assembly

2 00102044 ECU BOX Mounting Bracket

3 R006-0002-0007 ECU Box Mounting Bracket Hardware Nylon Insert Locknut 3/8-16

4 00102030 ECU Box Frame Clamp

5 R006-0001-0016 ECU Box Frame Clamp Hardware 3/8-16UNC x 1" LG SHSC

6 00102036 ECU Box lower Shield

7&8 00102183 Inertia Switch / 7.5A Fuse and Holder

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

10 91003004 Thermocouple x 2

11 00102129 Fuel Reservoir w/shut off valve & fittings

12 R008-001-0006 Driver's LED Display

13 R008-0001-0002 Wire Harness

14 00102151 1/4” x 54” w/ #4-3/8” NTP fittings x 2 Backpressure Hose w/fittings

15 00102153 1/4” x 66” w/ #4-3/8” NTP fittings x 2 ECU-Fuel Supply Hose w/fittings





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ThermaCat Diesel Fuel Injection Nozzle Assembly Exploded Drawing

Fig. 49


29 N/A Inlet Exhaust Pipe

30 91002002 Injector Assembly Gasket

31 E910-S002-A Fuel Injector Assembly w/4mm steel line

32 R006-0006-0009 Injector Assembly Band Clamp for 4" Tube





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ThermaCat™ ECU Enclosure Exploded Drawing

Fig. 50

ITEM # PART NUMBER DESCRIPTION QTY.

1 91001049 ECU ENCLOSURE WITH FITTINGS 1

2 91001020 ECU/WATER SEPARATOR MOUNTED 1

3 R008-0001-0182 FUEL FILTER 1

4 R001-0002-0019 316 SS 4mm DIA 0.5mm WALL TUBE ANNEALED, 9 7/8" LENGTH 1

5 R008-0001-0002 WIRE HARNESS 1

6 R006-0007-0002 CABLE TIE 12" 2

7 R006-0007-0002 CABLE TIE 12" 1

8 R008-0001-0136 CABLE TIE 4" 1

9 R006-0009-0004 #8 HOSE CLAMP 4

10 R006-0009-0005 #24 HOSE CLAMP 1

11 R008-0001-0039 Fuel hose - ¼” ID x 10” 1

12 R008-0001-0039 Fuel hose - ¼“ ID x 16” 1

13 R008-0001-0018 5/32" OD NYLON TUBE, 14" LENGTH 1

14 R008-0001-0018 5/32" OD NYLON TUBE, 7" LENGTH 1





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15 R008-0001-0018 5/32" OD NYLON TUBE. 10" LENGTH 1

ThermaCat™ Engine Tag Installation

52) 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. 51 Fig. 52

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