Modine MCI J3500 EFAN User/Troubleshooting Guide

Modine
Brand
Modine
Model
MCI J3500 EFAN
Category
Motorcycle Accessories
Type
User/Troubleshooting Guide
NEW FLYER Xcelsior / MCI J3500
EFAN Service Manual and
Diagnostic Software User Guide
8A003359 Rev M
Last Revised: 1/8/2021
EFAN Troubleshooting Guide Latest Revision:1/8/2021
1/46
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
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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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
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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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
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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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
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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Section 3: Connector Definitions
#
Name
Description
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
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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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.
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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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
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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Section 4: Connector Locations
1A021355-356-384-385-464-465-466-466-467-640-662 – 8 Fan Cooling
Module
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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EFAN Troubleshooting Guide Latest Revision:1/8/2021
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1A021464-465-466-467-660 – 8 Fan Cooling Module – High Powered Fans
EFAN Troubleshooting Guide Latest Revision:1/8/2021
13/46
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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1A021386-387-388-389-470-471-472-473-553-554-573-574-643-698-699 – 9
Fan Cooling Module
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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EFAN Troubleshooting Guide Latest Revision:1/8/2021
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1A021734 and PR0448430001 - PR0443980001 – 9 Fan Cooling Module Fuel
Cell Bus
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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EFAN Troubleshooting Guide Latest Revision:1/8/2021
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1A021456-457 – 2 Fan Cooling Module – BAE Hybrid MCP
EFAN Troubleshooting Guide Latest Revision:1/8/2021
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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
Brand
Modine
Model
MCI J3500 EFAN
Category
Motorcycle Accessories
Type
User/Troubleshooting Guide
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