NEW FLYER Xcelsior / MCI J3500 EFAN Service Manual and Diagnostic Software User Guide 8A003359 Rev L Last Revised: 1/3/2020

EFAN Troubleshooting Guide Latest Revision:1/3/2020 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 PR0448430001 - PR0443980001 – 8 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 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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EFAN Troubleshooting Guide Latest Revision:1/3/2020 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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EFAN Troubleshooting Guide Latest Revision:1/3/2020 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

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Section 2: Modine Part # Identification

Vehicle Vehicle Vehicle Description Modine Part # OEM Model

MCI J3500 Cummins Engine – Voith/Allison/ZF 1A0216620000/1/2/3 Transmission

New Xcelsior 8 Fan Cooling Module Cummins Engine – 1A021355-356-384- Flyer Voith/Allison/ZF Transmission 385-464-465-466- 467- 1A021640000/1/2/3 1A0216600000/1/2/3

New Xcelsior 9 Fan Cooling Module Cummins ISLG320 1A021386-387-388- Flyer Engine – Voith/Allison/ZF Transmission 389- 1A0216430000/1

New Xcelsior 9 Fan Cooling Module Cummins Engine – BAE 1A021470-471-472- Flyer or Allison Hybrid 473-553-554-573- 574- 1A0216980000/1- 1A0216990000/1

New Xcelsior 9 Fan Cooling Module Fuel Cell Bus PR0448430001 / Flyer PR0443980001

New Xcelsior 3 Fan Cooling Module BAE Hybrid Bus MCP 1A021456-457 Flyer Cooling Circuit

New Xcelsior 2 Fan Cooling Module BAE Hybrid Bus ECP 1A021454-455 Flyer Cooling Circuit

New Xcelsior 4 Fan Cooling Module Allison Hybrid Bus 1A021468-469 Flyer

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Section 3: Connector Definitions # Name Description Pictoral RS232 connector used for connecting to 1. Square RS232 controller for firmware re-programming and datalog downloading

2. Fuse & Holder 30A fuse to protect wires to each individual – Fan (30A) E-fan

Fuse & Holder 3. – Controller 5A fuse to protect wires to controller (5A)

Fuse & Holder 40A fuse to protect wires to each individual 4. – Fan (40A) E-fan

Power & Studs to connect system to bus 5. Ground Studs power/ground

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 HDP Pin J – Fan Power 6. Connector 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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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Pin A - Ignition, Red - Input Pin B - Reverse, Blue - Input Pin C - Fire, Purple - Input 7. Flat 6-pin Pin D – Status to Diagnostic Bulb, Brown - Output Pin E – Controller Ground, Black Pin A – Fire, Purple - Input Pin B – Ignition, Red – Input Pin C – Reverse, Blue – Input 8-Pin Pin D – Status to Diagnostic Bulb, Brown - 8. Metripack Output Pin E – Controller Ground, Black Pin G – CAN J1939 +, Yellow

Pin H – CAN J1939 -, Green

J1939 (CAN) connection between E-fan 9. J1939 (CAN) Cooling Module and bus interface

Controller 10. Connector – 30 pin

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

NO CONNECT

Controller 11. Connector – 18 pin

Busbar used to connect PWM output from controller to bank of E-fans. One busbar for 12. Busbar (PWM) CAC fan bank and one busbar for Radiator fan bank.

Busbar Busbar used to connect vechicle ignition 13. (Ignition input and provide output to controller and Failsafe) each individual E-fan.

Pin E – Power, Red Fan Connector Pin G – Ground, Black – Fan Side 14. Pin B – PWM, Yellow (4100 RPM Pin C – Fault / Diagnostic Wire, White Fan) Pin F – Ignition Failsafe, Red or Black

Pin E – Power, Red Fan Connector Pin G – Ground, Black – Harness Side 15. Pin B – PWM, Yellow (4100 RPM Pin C – Fault / Diagnostic Wire, White Fan) Pin F – Ignition Failsafe, Red or Black

Pin A – Power, Red Fan Connector Pin C – Ground, Black – Fan Side 16. Pin D – PWM, Yellow (4750 RPM Pin F – Fault / Diagnostic Wire, White Fan) Pin E – Ignition Failsafe, Red or Black

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

Pin A – Power, Red Fan Connector Pin C – Ground, Black – Harness Side 17. Pin D – PWM, Yellow (4750 RPM Pin F – Fault / Diagnostic Wire, White Fan) Pin E – Ignition Failsafe, Red or Black

Pin 1 - CAN J1939 +, Yellow Electric Pump Pin 2 – CAN J1939, Drain Signal 18. Pin 4 – CAN Address Loop, Short Connector – Pin 5 – CAN Address Loop, Short Pump Side Pin 6 - CAN J1939 -, Green

Pin 1 - CAN J1939 +, Yellow Electric Pump Pin 2 – CAN J1939, Drain Signal 19. Pin 4 – CAN Address Loop, Short Connector – Pin 5 – CAN Address Loop, Short Harness Side Pin 6 - CAN J1939 -, Green

Electric Pump Power Pin 2 – Electric Pump Ground 20. Connector – Pin 3 – Electric Pump Power Pump Side

Electric Pump Power Pin 2 – Electric Pump Ground 21. Connector – Pin 3 – Electric Pump Power Harness Side

Main system controller. Controller part # 22. Controller printed on front label.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

Typically provided by OEM Diagnostic OEM rear run box typically includes reverse 23. Bulb / Reverse switch and diagnostic bulb together in rear Switch run box panel

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Section 4: Connector Locations

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

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 1A021464-465-466-467-660 – 8 Fan Cooling Module – High Powered Fans

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 1A021386-387-388-389-470-471-472-473-553-554-573-574-643-698-699 – 9 Fan Cooling Module

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 PR0448430001 - PR0443980001 – 8 Fan Cooling Module Fuel Cell Bus

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 1A021456-457 – 2 Fan Cooling Module – BAE Hybrid MCP

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 1A021454-455 – 2 Fan Cooling Module – BAE Hybrid ECP

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 1A021468-469 – 4 Fan Cooling Module – Allison Hybrid

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Section 5: Normal Operating Conditions Normal system response can be verified by the engine on conditions below and by running the reverse sequence.

Engine On 1. CAC fans running slowly 2. Diagnostic bulb illuminates for the first 3 seconds to indicate controller power is on and then remains off 3. Radiator / Hybrid Fans will operate based on demand from engine / hybrid as defined below

Fan Operation – Fan # Layout (Modine Part #’s 1A021355-356-384-385-464-- 467-640-660-662) Charge air cooler (CAC) fans Radiator (RAD) fans Run at minimum speed when Do not run until coolant temperature reaches engine starts 196°F (91°C)

1 2

3 4 5

6 7 8

Note: All CACs fans turn on together at the same speed when commanded and all Radiator fans turn on together at the same speed when commanded.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fan Operation – Fan # Layout (Modine Part #’s 1A021386-387-388-389-643) Charge air cooler (CAC) fans Radiator (RAD) fans Run at minimum speed when Do not run until coolant temperature reaches engine starts 196°F (91°C)

1 2 3

5 6

4 7 8 9

Note: All CACs fans turn on together at the same speed when commanded and all Radiator fans turn on together at the same speed when commanded.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fan Operation – Fan # Layout (Modine Part #’s 1A021470-471-472-473-553- 554-573-574-698-699) Charge air cooler Allison / BAE Hybrid Radiator (RAD) fans (CAC) fans fans Run at minimum Do not run until coolant Do not run until speed when engine temperature reaches 196°F hybrid demand is starts (91°C) received

1 2 3

5 6

4 7 8 9

Note: All CACs fans turn on together at the same speed when commanded and all Radiator fans turn on together and Oil Cooler fans turn on together at the same speed when commanded.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fan Operation – Fan # Layout (Modine Part #’s PR0448430001 - PR0443980001) Radiator (RAD) fans Fans will run when there is a fan request from the fuel cell via command message 0xE04E27.

1 2 3 5 6

4 7 8 9

Note: All radiator fans turn on together at the same speed when commanded and all radiator fans turn off together when commanded.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fan Operation – Fan # Layout (Modine Part #’s 1A021456-457)

BAE MCP Hybrid fans Do not run until hybrid demand is received

1 2 3

Fan Operation – Fan # Layout (Modine Part #’s 1A021454-455) BAE ECP Hybrid fans

Do not run until hybrid demand is received

1 2

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fan Operation – Fan # Layout (Modine Part #’s 1A021468-469) Allison Hybrid fans

Do not run until hybrid demand is received

1 2

3 4

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Diagnostic Bulb

Bulb State Meaning Off System is running normally On CAN communication with module has been lost Flashing – 1 second on, 1 second off Fans running in reverse sequence, use to check bulb Flashing – Long and short duration Indicates which fan(s) have failed. Short flashes indicate fan number, multiple numbers are separated by long pause On for 3 seconds during initial Indicates controller is powered on. Light must turn controller power up off after initial startup Note: See Troubleshooting Section if CAN Communication is lost or a fan failure has occurred.

Reverse Switch (use to check if all fans are working – Not installed for Rooftop Modules) Press switch momentarily to activate reverse sequence. Fans will run in reverse for about 15 seconds. Diagnostic bulb will flash during this time. This sequence may be aborted by pressing switch again.

Note: ignition must be on and the fire override (gravity switch on fan door, if installed by OEM, and any other fire override inputs from fire suppression system or IO multiplexer that OEM uses) must be off to run reverse sequence. This may be accomplished by keeping fan door closed or temporarily disconnecting switch.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

Press to run fans in reverse

Press again to abort

Section 6: Failsafe Feature Operating Conditions Two failsafe feature operating conditions were put in place to protect the vehicle from an overheat event. These are not normal operating conditions and require further troubleshooting if they occur.

1. CAN Communication Loss Protection – Controller will request fans to run at a default speed near full speed. 2. Ignition Failsafe Loss Protection – In the event that the controller fails or loses power and the ignition wire to the fans is +24V the fans will run at a default speed near full speed.

Section 7: Diagnostic Software The Modine Universal Diagnostic Software (UDS) package has the following functions:

• Monitor system response in real time • Control cooling module manually • Download internal data log (RS-232 cable required, Modine PN: 3S0586190000)

Supported Devices All RP1210 compliant J1939 data link adapters are supported. Examples include the NexIQ USB-Link (PN: 125032) and the Cummins INLINE 6 (PN: 2892093).

Downloading Diagnostic Software 1. Enter (or click) the following address in your default internet browser: http://www.modine.com/transitsoftware a. Or you can perform the following steps. i. Navigate to www.modine.com ii. Navigate to Products > Transit Bus tab iii. Click on Troubleshooting & Diagnostics on the left side of the screen. iv. Click the Transit Diagnostic Software Link 2. Download and run the setup.exe file. 3. There should now be a “Modine UDS” program in your Start Menu.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Connecting to Built-in Diagnostic System 1. Make sure the latest version of Modine UDS is installed on computer that will be used for troubleshooting. See previous section. 2. Connect one of the supported data link adapters, outlined above. Drivers must be obtained through the manufacturer’s website and installed. 3. Launch Modine UDS and turn on vehicle to power up controller. 4. If this is the first time running Modine UDS with a given datalink adapter:

a. Select the “Connect RP1210 Adapter” button. b. A dialog will appear. First select the Manufacturer driver, then the Device connected to the PC. This list is populated with all drivers installed on the PC.

c. Press OK to confirm selection. If connection is unsuccessful, another selection may be attempted. If connection is successful, Modine UDS will remember the selection and automatically connect the last successful device when the program is run again. 5. The bottom of the main window will display connection status along with controller part number and revision level. See image below.

6. The EFAN system status may now be monitored, fans may be manually controlled, and histogram data may be downloaded (if equipped).

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Manual Control 1. To enable manual control, check the box next to Manual Control. The fan speed will now reflect the fan speed entered in the boxes below (0-100%).

2. The fans will run at the nearest increment to the entered value. Note that this will likely not reflect the exact value entered. If the coolant temperature exceeds 99°C (210°F) or if SPN 986 – Percent Fan Request reaches 100, manual mode will be disabled until temperatures decrease. 3. Once the Manual Mode check box is unchecked, fans will resume normal operation.

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Interpreting Data 1. Gauges that are grey indicate that there is no J1939 message present.

2. Red fan gauges indicate a fan failure. In this case, fan 3 is failed.

3. Any active DM1 fault messages will be displayed in the message box at the bottom of the screen.

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Downloading Data Log 1. If Windows does not recognize the USB diagnostic cable, download the driver here: http://www.ftdichip.com/Drivers/CDM/CDM%20v2.12.06%20WHQL%20Certified.exe 2. Open Modine UDS 3. With the controller on, connect the USB diagnostic cable

4. Click the Download Fault Log button near the bottom of the screen. 5. Select the COM port assigned to the cable. 6. When data has been successfully downloaded, a CSV file with the time/date of download will be placed in C:\ModineFaultLogs\

Data Log Triggers If any of the triggers listed below occur, the controller will record a log file that can be downloaded for diagnostic and system analysis

See Section 5: Troubleshooting - Failure Reported Via CAN or Controller Data log for troubleshooting activities.

Trigger Condition High Coolant Temp J1939 coolant temp is greater than 225°F (107°C) Under or Over Voltage at Controller Voltage at controller is < 16 VDC or > 32 VDC Fan Failure One or more fans are not running when they should be High Controller Temp Internal controller temperature is greater than 176°F (80°C) CAN Communication loss CAN/J1939 cable disconnected from controller

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Section 8: Troubleshooting

Fans Do Not Run When They Are Supposed To Possible Cause Remedy See Flowchart below for step-by-step diagnosing Fire Override Replace fire override tilt Tilt switch active (if present). Active switch. (+24 V on Pin C of 6 Fire override active from IO Consult OEM pin). multiplexer/fire suppression input. Troubleshoot CAN Incorrect PWM output from controller – (3% is Off, 40% is Connection. Replace min speed, 92% is max speed) controller. Blown fan fuse or OEM module fuse. Replace blown fuse. Inspect power & ground studs to make Fan(s) not sure there is no corrosion and ring receiving +24V terminals are secure. Corrosion on fan connector wires. Inspect power & ground studs to make Loss of ground sure there is no corrosion and ring Clean wires and replace connection terminals are secure. terminals, seals and Corrosion on fan connector wires. connectors as needed.

If no continuity exists on white diagnostic wire between fan and controller. Ensure all connectors are connected correctly. Reported fan failure when fan is operating normally If continuity exists on white diagnostic wire between fan and controller. Replace fan, bad internal power/ground or PWM connection. Apply +24V to power and PWM Failed fan wiring or cavities and ground to ground cavity of fan motor individual fan. Wait 15 seconds; fan should begin to spin near full speed.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fans do not Checklist for fans to run Check fan fuses • +24V on Power (thicker red wire on fan connector) run when they Check busbar and OEM module • 0V on Ground (black wire on fan connector) caps are supposed fuse • +24V on Ignition (thinner red wire on fan connector) to • +24V for full speed on PWM (yellow wire on fan connector)

Reverse feature is a good way to test functionality

Diagnostic line (white wire) outputs +24V when fan is running No fans run Some fans run Fan ignition wire- if 0V is present on fan ignition cavity and vehicle ignition and controller are both on, fan will operate in normal condition. 0V on fan ignition cavity means ignition failsafe feature in the event of a controller failure, is disabled.

Repair reverse switch. Blue wire. Does diagnostic light flash Ensure it supplies once per second when No 24V to controller reverse switch is activated when thrown. Also and ignition is on ensure diagnostic light is functioning

Yes

Failed fans correspond to a Consult OEM/ fan bank? Disconnect the fire troubleshoot fire override switch Is Fire Override activate? Yes suppression connector (if system or IO equipped) multiplexer Yes

Inspect ignition Is there +24V on fan Is controller PWM output connection on flat Yes connector ignition line when No correct? 6-pin connector vehicle ignition is on? and ignition busbar Next Page

No Yes

Troubleshoot CAN Communication or Replace Controller Trace power lines back to vehicle connection check fuses and depending on model either: Is there +24V on the fan No A) ensure HDP connector is connector power line? properly seated or B) ensure ring terminals are secure and clean

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Replace fan (bad internal diagnostic wire).

Inspect Power & Ground studs. Make Yes sure there is no corrosion and ring terminals are secure. Is there continuity between fan connector diagnostic wire Replace terminals and seals (as No and controller 30-pin needed). connector?

Does reported fan failure go Do the fans in question run away? Use external Replace terminals and seals (as Yes Yes appropriately? diagnostic bulb/UDS to needed). verify.

Fan functionality may be checked by Inspect fan applying system voltage (usually +24V) connector. Look to fan power wire and PWM wire and for corrosion or ground to fan ground wire. Fan should loose terminals run near full speed.

Note: Swapping a fan that runs with a fan that does not run will determine if the failed condition follows the wire harness or the specific fan. Run reverse feature for quick feedback on fan performance.

Replace Fan No Does fan run?

Yes

Replace terminals, seals and connectors (as needed).

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fans Run When They Are Not Supposed To or Failsafe Features Activated Possible Cause Remedy

See Flowchart below for step-by-step diagnosing

Inspect ground stud to make sure there is no corrosion and ring Loss of fan terminals are secure. ground Clean wires and replace terminals, connection Corrosion on fan connector wires seals and connectors. Check continuity on PWM wire Fan not receiving from fan to PWM busbar to Clean wires and replace terminals, PWM output from controller PWM output cavity and seals, connectors and PWM controller ensure all connectors are properly busbar caps as needed. seated. See “CAN Communication Loss” CAN Communication Loss troubleshooting section. Replace 5A fuse, ignition busbar, Controller not wiring harness or wiring harness Check voltages at 5A fuse, Ignition receiving +24V section. Clean wires and replace busbar, flat 6-pin (pin A). (+/- 5 volts) terminals, seals and connectors as needed Verify +24V (+/- 5 volts) volts is across pins H2 (30 pin) and F1 (18 Failed Controller Replace controller pin) and that 18 and 30 pin connectors are properly seated. Check individual fan connectors Voltage on fan and PWM busbars for water PWM wire when penetration or corrosion. Verify Clean wires and replace terminals vehicle ignition is greater than 0V exists on fan seals and connectors. off PWM wire when PWM busbar is removed.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

Fans run when they are not Replace Controller supposed to

Yes

24V (+/-5V) between Inspect power & Does Diagnostic LED controller pins 30-H2 and 18- ground studs to make Controller Failsafe illuminate for 3 seconds F1? Make sure 30 and 18- No Yes sure there is no is Active when ignition is keyed on? pin connectors are clean and corrosion and ring (Normal controller power on) secure to controller. terminals are secure.

Replace 5A fuse, PWM busbar, wiring harness or wiring harness section (as Check ground wire needed). connection. Flat 6-pin Does an entire bank of fans connector or ring terminal continue to run? at OEM chassis ground. No

Yes Yes Check 5A controller fuse Is there +24V on each of the components? Disconnect PWM busbars and ignition busbar to determine which individual fan runs by itself. No

24V (+/-5V) between Check voltage at Do any fans controller pins 30-H2 and 18- 5A fuse, PWM continue to run? F1? Make sure 30 and 18- No busar and ignition pin connectors are clean and wire on flat 6-pin Yes No secure to controller. connector

Inspect connector on fans that continue to run. Look for water creating a connection between the Yes red ignition or power wires and the yellow PWM wire. Verify greater than 0V exists on PWM line.

Verify system operates normally. Reinstall PWM and ignition busbars. Reinstall PWM and ignition busbars. Inspect for continuity between PWM Inspect for continuity between PWM busbar and individual fan PWM wire. Make busbar and controller PWM output. Make sure all connectors are sealed and sure all connectors are sealed and connected correctly. connected correctly.

Replace terminals, seals and connectors (as needed).

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Failure Reported Via CAN or Controller Data Log

The following are the current controller recognized fault codes for the internal data logger: The trigger that created the data log file is located at the bottom row of the log event. Note: Controller can store roughly 100 events and they are first in first out.

High Coolant Temp Alarm From Engine Possible Cause Remedy

See Flowchart below for step-by-step diagnosing

Fire mode input on (value = 1). Fans do not run See “Fans Do Not Run When They when they are Fans in present state show Are Supposed To” troubleshooting supposed to they are not running when section. supposed to. Clean cores with low pressure, high Heat exchanger cores clogged flow water. Cooling system leak Replace damaged component.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

High Coolant Temp Alarm From Engine

See “Fans Do Not Run Is “Fire Mode Input When They Are Supposed Yes On/Off” value = 1? To” troubleshooting section for fire override active. See “Fans Do Not Run When They Are Supposed To” troubleshooting section No No

Are the fans operating Are all “Fan # Status” See “Fans Do Not Run When They Are Yes No correctly? columns = 1? Supposed To” for diagnosing fan failure.

Yes

Are the heat exchangers Replace damaged heat Yes damaged/leaking? exchangers

Clean heat exchangers with low pressure/high flow water

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EFAN Troubleshooting Guide Latest Revision:1/3/2020

Under or Over Voltage Level at Controller Possible Cause Remedy

See Flowchart below for step-by-step diagnosing

Controller not receiving +24V Inspect ignition connection on 6-pin vehicle connector

Inspect ground connection on 6-pin vehicle connector. Loss of ground connection Trace back to bus ground and troubleshoot. Poor voltage regulator/battery Troubleshoot voltage regulator/battery charging system. charging system Consult OEM.

Under or Over Voltage Level at Controller

Inspect IGNITION Inspect GROUND wire on flat 6-pin wire on flat 6-pin vehicle connector vehicle connector

Troubleshoot IGNITION Is there +24V on Is there -24V on Troubleshoot GROUND No No source/connection IGN line? GROUND line? source/connection

Yes Yes

Is the voltage regulator Troubleshoot voltage regulator/battery and/or battery charging Replace terminals and seals on No Yes charging system. Consult OEM system operating flat 6-pin IGN/GND correctly?

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Fan Failure When a fan failure is reported in the log file, review the “Fan # Status” columns to determine which fan failure location has been identified. A value of 1 means the fan it working, a value of 0 indicates a fan fault. See the “Fans Do Not Run When They are Supposed To” Section for further troubleshooting.

High Controller Internal Temperature Possible Cause Remedy

See Flowchart below for step-by-step diagnosing

Excessive hot air Inspect cooling system air seals Consult OEM to eliminate air recirculation near controller. recirculation. Inspect mounting of controller Controller and match location listed in Secure controller in original improperly mounted “Location of Connectors” location. section

Faulty controller circuitry Replace controller.

Reported High Internal Controller Temperature

Is the controller Is there excessive hot air mounted correctly Secure controller recirculation coming from the engine No No and in appropriate correctly compartment? location?

Yes Yes

Consult OEM to eliminate air Replace controller recirculation

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CAN Communication Loss Possible Cause Remedy

See Flowchart below for step-by-step diagnosing Loose CAN Inspect 3-way Deutsche CAN Replace terminals, seals and connection at connector connectors. controller Troubleshoot CAN network. External CAN device interference Consult OEM Troubleshoot ECU to accept Vehicle ECU Incorrectly configured for E-fan variable speed fan. Consult OEM.

Receive CAN Communication Loss error from controller or CAN system

Make sure: 3-pin triangle connector is secured Terminating resistor is installed in Y- connector, if equipped Check input statuses using UDS

Check for external devices on CAN Test for short circuit: Is CAN communication Yes network that may Voltage between +24V functioning? disturb controller (battery voltage) and CAN function HIGH and CAN LOW should be between 0 and battery voltage – Test with ignition on battery connected Ensure vehicle No ECU is properly configured for EFAN system Test for open circuit: Resistance on CAN Inspect 3-pin network should be 60 +/- 6 triangle CAN Ohms – test with Ignition connector off and battery disconnected Consult OEM

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Section 9: Maintenance For all additional preventative maintenance requirements for the cooling system consult the New Flyer published preventative maintenance documents.

Weekly Inspections • Test the function of the fan reverse switch and LED indicator. Operating the fan reverse switch will clear debris from the heat exchanger cores, and will also confirm operation of the LED indicator which is used to display diagnostic fault codes. Note: Reverse switch not installed for rooftop modules.

Yearly Inspections • Inspect the main positive and negative power cables for wear or frayed insulation. Ensure the protective rubber boots are in place and in good condition (for modules using power/ground studs). • Check the main power cable connections for tightness and torque to 20 Nm (for modules using power/ground studs). • Inspect the condition of the inner and outer nylon bushings on the main power cable pass- through studs (for modules using power/ground studs.) • Inspect main wiring harness and connections to the system controller and all fans • Inspect fuses and fuse holders. • Inspect support structure for any damage or loose mounting hardware. • Visually inspect heat exchangers for signs of core clogging. Use low pressure water spray to remove any signs of debris.

Fan Replacement When replacing a fan, be sure not over tighten the mounting hardware (6ft-lbs). Ensure wire hand guard is installed and not obstructing fan blade. When connecting to the wire harness, verify all connections are clean and free of corrosion prior to connecting. Coat wire harness side in dielectric grease and insert to fan connector verifying the orange seal is not pinched and is fully inserted. Use the provided cable ties and insert through locking feature on connector prior to attaching to the shroud. Reference Modine document 8A003349 for crimping instructions (will be included in any service kit purchase).

Fuse/General Connector Replacement All fan fuses use 30 amp maxi-fuses and are labeled with the corresponding fan numbers (see section 2 for fan numbering scheme). The IO controller uses a 5 amp mini-fuse.

Reference Modine document 8A003349 for crimping instructions (will be included in any service kit purchase).

Welding Guidelines Prior to welding, ensure master battery switch is off, power and ground cables are removed from the cooling system and all J1939 (CAN) as well as ignition lines are disconnected from e-fan. Complete this

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 by disconnecting the 8-pin receptacle (see section 1 for identification). Ensure welder ground is in close proximity to the point of weld and is not connected to the cooling system frame or heat exchangers. Once work is completed, ensure all cables and connectors are connected properly prior to testing the system.

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Appendix B – J1939 Messages

DM1 Fault Messages Table below is for typical 8 fan module system. Other systems with differing fan quantities will follow the same pattern. For example, a 9 fan system will use J1939 SPN 521509 for the 9th fan location.

Internal J1939 J1939 J1939 Diagnostic Data log Fault Type Source Description SPN FMI Lamp Lamp trigger? Fan 1 Inoperable 521501 1 Fan 2 Inoperable Diagnostic 521502 1 Fan 3 Inoperable feedback from fan 521503 1 Flash Fan 4 Inoperable motor indicates 521504 1 corresponding Fan Motor None Yes Fan 5 Inoperable that fan blades are 521505 1 to failed fan Fan 6 Inoperable not spinning when 521506 1 number Fan 7 Inoperable commanded to 521507 1 Fan 8 Inoperable 521508 1 Fan 1 J1939 Failsafe Mode Fans are running 521501 2 Fan 2 J1939 Failsafe Mode properly but 521502 2 Fan 3 J1939 Failsafe Mode operating 521503 2 Fan 4 J1939 Failsafe Mode conditions form 521504 2 Controller None Solid ON Yes Fan 5 J1939 Failsafe Mode the vehicle CAN 521505 2 Fan 6 J1939 Failsafe Mode bus have been lost. 521506 2 Fan 7 J1939 Failsafe Mode Fans are running at 521507 2 Fan 8 J1939 Failsafe Mode failsafe speed 521508 2 Voltage at the Controller system controller None None Yes Over-Voltage above 32V 521201 0 Voltage at the Controller system controller None None Yes Under-Voltage below 17V 521202 1 Fire Override input Controller None None No Fire Override Active is active 521204 0 Flash at 1 Hz Controller is in Controller None during No reverse sequence Reverse Active 521205 0 sequence

Performance Messages Byte Rate Description Pri PGN SA [1-8] Factor Offset Units [ms] Notes PWM % - Fan Bank 1 18 B100 4E 5 0.4 0 % 1000 Minimum fan speed = 40% PWM PWM % - Fan Bank 2 18 B200 4E 5 0.4 0 % 1000 Maximum fan speed ≥ 90% PWM PWM % - Fan Bank 3 18 B300 4E 5 0.4 0 % 1000 System Identification Length Description Pri PGN SA Rate [bytes] Data Request message 18 EA4E Any N/A 3 18 EA 00 Controller Part Number 18 FEDA 4E On Request 8 Byte 2-6 = Last 5 digits of controller part number Firmware Revision 18 FEDA 4E On Request 8 Byte 7 = Firmware revision

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EFAN Troubleshooting Guide Latest Revision:1/3/2020 Revision Log

Revision Description Date CR A Released to production. 12/18/2015 B Minor formatting updates, removed HDP, replaced RTMD 7/12/2016 C Updated Title of Document 2/13/2017 D Added DM1 and J1939 Messages 3/2/2017 4007098 E Removed Common Service Parts Appendix. Updated 3/23/2017 4007362 Maintenance Note F Added 9 Fan, 3-Fan, 2-Fan and 4-Fan Modules to document 4/24/2017 4007796 G Added 8 Fan High Power modules 1A021464-467. 5/5/2017 4007796 H Added 1A021553-554-573-574 modules 1/25/2018 I Added PR0448430001 and PR0443980001 modules 5/24/2018 J Added 1A021640/662 modules. Adjusted Section numbering and 11/13/2018 adding Section #2 K Added 1A021660 modules 7/23/2019 L Added 1A021643-698-699 9 Fan Modules 1/3/2020

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