Modine MCI J3500 EFAN User/Troubleshooting Guide

NEW FLYER Xcelsior / MCI J3500

EFAN Service Manual and

Diagnostic Software User Guide

8A003359 Rev M

Last Revised: 1/8/2021

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Table of Contents 
Section 1: Introduction _________________________________________________________  3 
Section 2: Modine Part # Identification ____________________________________________  4 
Section 3: Connector Definitions _________________________________________________  5 
Section 4: Connector Locations  _________________________________________________  10 
1A021355-356-384-385-464-465-466-466-467-640-662 – 8 Fan Cooling Module _______________ 10 
1A021464-465-466-467-660 – 8 Fan Cooling Module – High Powered Fans ___________________  12 
1A021386-387-388-389-470-471-472-473-553-554-573-574-643-698-699 – 9 Fan Cooling Module  14 
1A021734 and PR0448430001 -  PR0443980001 – 9 Fan Cooling Module Fuel Cell Bus __________ 16 
1A021456-457 – 2 Fan Cooling Module – BAE Hybrid MCP ________________________________ 18 
1A021454-455 – 2 Fan Cooling Module – BAE Hybrid ECP _________________________________  19 
1A021468-469 – 4 Fan Cooling Module – Allison Hybrid __________________________________ 20 
Section 5: Normal Operating Conditions __________________________________________  21 
Engine On _______________________________________________________________________  21 
Fan Operation – Fan # Layout (Modine Part #’s 1A021355-356-384-385-464--467-640-660-662) __  21 
Fan Operation – Fan # Layout (Modine Part #’s 1A021386-387-388-389-643) _________________  22 
Fan Operation – Fan # Layout (Modine Part #’s 1A021470-471-472-473-553-554-573-574-698-699) 23 
Fan Operation – Fan # Layout (Modine Part #’s 1A021734 and PR0448430001 -  PR0443980001) _  24 
Fan Operation – Fan # Layout (Modine Part #’s 1A021456-457) ____________________________  25 
Fan Operation – Fan # Layout (Modine Part #’s 1A021454-455) ____________________________  25 
Fan Operation – Fan # Layout (Modine Part #’s 1A021468-469) ____________________________  26 
Diagnostic Bulb ___________________________________________________________________  27 
Reverse Switch (use to check if all fans are working – Not installed for Rooftop Modules) _______  27 
Section 6: Failsafe Feature Operating Conditions ___________________________________  28 
Section 7: Diagnostic Software  _________________________________________________  28 
Supported Devices ________________________________________________________________  28 
Downloading Diagnostic Software  ___________________________________________________  28 
Connecting to Built-in Diagnostic System ______________________________________________ 29 
Manual Control ___________________________________________________________________ 30 
Interpreting Data _________________________________________________________________  31 

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Downloading Data Log _____________________________________________________________  32 
Section 8: Troubleshooting  ____________________________________________________  33 
Fans Do Not Run When They Are Supposed To  _________________________________________ 33 
Fans Run When They Are Not Supposed To or Failsafe Features Activated  ___________________  36 
Section 9: Maintenance _______________________________________________________  43 
Weekly Inspections  _______________________________________________________________ 43 
Yearly Inspections  ________________________________________________________________  43 
Fan Replacement _________________________________________________________________  43 
Fuse/General Connector Replacement ________________________________________________ 43 
Welding Guidelines  _______________________________________________________________ 43 
Appendix B – J1939 Messages __________________________________________________  45 
DM1 Fault Messages  ______________________________________________________________  45 
Performance Messages  ____________________________________________________________  45 
System Identification ______________________________________________________________  45 
Revision Log ________________________________________________________________  46 
 

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Section 1: Introduction

This guide instructs users of the Modine EFAN system on how to connect to its diagnostic system,

download data logs, monitor current status, and troubleshoot potential problems.

This troubleshooting guide applies to EFAN systems with the following controller Part Numbers:

• 5A0776800000 – Cummins Diesel/CNG with Allison or Voith Transmission – 8 Fan Module

• 5A0776810000 – Cummins Diesel/CNG with ZF Transmission – 8 Fan Module

• 5A0791790000 – Cummins 320CNG with Allison or Voith Transmission – 9 Fan Module

• 5A0796650000 – Cummins 320CNG with ZF Transmission – 9 Fan Module

• 5A0795740000 – BAE HDS100/200/300 MCP Rooftop Cooler – 3 Fan Module

• 5A0795240000 - BAE HDS100/200/300 ECP Rooftop Cooler – 2 Fan Module

• 5A0796210000 – Allison Hybrid Rooftop Cooler – 4 Fan Module

• 5A0807950000 – Fuel Cell Bus – 9 Fan Module

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Section 2: Modine Part # Identification

Vehicle

OEM

Vehicle

Model

Vehicle Description

Modine Part #

MCI

J3500

Cummins Engine – Voith/Allison/ZF

Transmission

1A0216620000/1/2/3

New

Flyer

Xcelsior

8 Fan Cooling Module Cummins Engine –

Voith/Allison/ZF Transmission

1A021355-356-384-

385-464-465-466-

467-

1A021640000/1/2/3

1A0216600000/1/2/3

New

Flyer

Xcelsior

9 Fan Cooling Module Cummins ISLG320

Engine – Voith/Allison/ZF Transmission

1A021386-387-388-

389-

1A0216430000/1

New

Flyer

Xcelsior

9 Fan Cooling Module Cummins Engine – BAE

or Allison Hybrid

1A021470-471-472-

473-553-554-573-

574-

1A0216980000/1-

1A0216990000/1

New

Flyer

Xcelsior

9 Fan Cooling Module Fuel Cell Bus

PR0448430001 /

PR0443980001

New

Flyer

Xcelsior

3 Fan Cooling Module BAE Hybrid Bus MCP

Cooling Circuit

1A021456-457

New

Flyer

Xcelsior

2 Fan Cooling Module BAE Hybrid Bus ECP

Cooling Circuit

1A021454-455

New

Flyer

Xcelsior

4 Fan Cooling Module Allison Hybrid Bus

1A021468-469

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Section 3: Connector Definitions

#

Name

Description

Pictoral

1.

Square RS232

RS232 connector used for connecting to

controller for firmware re-programming

and datalog downloading

2.

Fuse & Holder

– Fan (30A)

30A fuse to protect wires to each individual

E-fan

3.

Fuse & Holder

– Controller

(5A)

5A fuse to protect wires to controller

4.

Fuse & Holder

– Fan (40A)

40A fuse to protect wires to each individual

E-fan

5.

Power &

Ground Studs

Studs to connect system to bus

power/ground

6.

HDP

Connector

Pin B – Reverse, Blue - Input

Pin D – Ignition – Red – input

Pin E – Status to Diagnostic Bulb, Brown -

Output

Pin F – Fan Ground

Pin G – Fan Power

Pin J – Fan Power

Pin K – Fan Power

Pin L – Fan Power

Pin M – Fan Ground

Pin N – Fan Ground

Pin P – Fan Ground

Pin R – Controller Ground, Black

Pin S – Fire – Purple - Input

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7.

Flat 6-pin

Pin A - Ignition, Red - Input

Pin B - Reverse, Blue - Input

Pin C - Fire, Purple - Input

Pin D – Status to Diagnostic Bulb, Brown -

Output

Pin E – Controller Ground, Black

8.

8-Pin

Metripack

Pin A – Fire, Purple - Input

Pin B – Ignition, Red – Input

Pin C – Reverse, Blue – Input

Pin D – Status to Diagnostic Bulb, Brown -

Output

Pin E – Controller Ground, Black

Pin G – CAN J1939 +, Yellow

Pin H – CAN J1939 -, Green

9.

J1939 (CAN)

J1939 (CAN) connection between E-fan

Cooling Module and bus interface

10.

Controller

Connector –

30 pin

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11.

Controller

Connector –

18 pin

12.

Busbar (PWM)

Busbar used to connect PWM output from

controller to bank of E-fans. One busbar for

CAC fan bank and one busbar for Radiator

fan bank.

13.

Busbar

(Ignition

Failsafe)

Busbar used to connect vechicle ignition

input and provide output to controller and

each individual E-fan.

14.

Fan Connector

– Fan Side

(4100 RPM

Fan)

Pin E – Power, Red

Pin G – Ground, Black

Pin B – PWM, Yellow

Pin C – Fault / Diagnostic Wire, White

Pin F – Ignition Failsafe, Red or Black

15.

Fan Connector

– Harness Side

(4100 RPM

Fan)

Pin E – Power, Red

Pin G – Ground, Black

Pin B – PWM, Yellow

Pin C – Fault / Diagnostic Wire, White

Pin F – Ignition Failsafe, Red or Black

16.

Fan Connector

– Fan Side

(4750 RPM

Fan)

Pin A – Power, Red

Pin C – Ground, Black

Pin D – PWM, Yellow

Pin F – Fault / Diagnostic Wire, White

Pin E – Ignition Failsafe, Red or Black

NO CONNECT

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17.

Fan Connector

– Harness Side

(4750 RPM

Fan)

Pin A – Power, Red

Pin C – Ground, Black

Pin D – PWM, Yellow

Pin F – Fault / Diagnostic Wire, White

Pin E – Ignition Failsafe, Red or Black

18.

Electric Pump

Signal

Connector –

Pump Side

Pin 1 - CAN J1939 +, Yellow

Pin 2 – CAN J1939, Drain

Pin 4 – CAN Address Loop, Short

Pin 5 – CAN Address Loop, Short

Pin 6 - CAN J1939 -, Green

19.

Electric Pump

Signal

Connector –

Harness Side

Pin 1 - CAN J1939 +, Yellow

Pin 2 – CAN J1939, Drain

Pin 4 – CAN Address Loop, Short

Pin 5 – CAN Address Loop, Short

Pin 6 - CAN J1939 -, Green

20.

Electric Pump

Power

Connector –

Pump Side

Pin 2 – Electric Pump Ground

Pin 3 – Electric Pump Power

21.

Electric Pump

Power

Connector –

Harness Side

Pin 2 – Electric Pump Ground

Pin 3 – Electric Pump Power

22.

Controller

Main system controller. Controller part #

printed on front label.

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23.

Diagnostic

Bulb / Reverse

Switch

Typically provided by OEM

OEM rear run box typically includes reverse

switch and diagnostic bulb together in rear

run box panel

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Section 4: Connector Locations

1A021355-356-384-385-464-465-466-466-467-640-662 – 8 Fan Cooling

Module

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1A021464-465-466-467-660 – 8 Fan Cooling Module – High Powered Fans

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1A021386-387-388-389-470-471-472-473-553-554-573-574-643-698-699 – 9

Fan Cooling Module

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1A021734 and PR0448430001 - PR0443980001 – 9 Fan Cooling Module Fuel

Cell Bus

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1A021456-457 – 2 Fan Cooling Module – BAE Hybrid MCP

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1A021454-455 – 2 Fan Cooling Module – BAE Hybrid ECP

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Modine MCI J3500 EFAN User/Troubleshooting Guide

Modine MCI J3500 EFAN User/Troubleshooting Guide

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