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Access to CAC in 05 Inspire

Yahoo Message Number: 79852
Greetings campers and shadetree mechanics!
I'm doing some on-the-fly troubleshooting and would appreciate some advice.
I have been experiencing an intermittent engine warning light that is brief enough to not create a loggable event, but shows up as low boost on a CAT computer. The warning appears under heavier than normal load, and is more frequent before the engine temps settle at normal running levels.
My air filter has been replaced and my hoses inspected. I suspect a small leak somewhere, possibly the charge air cooler.
Where is the CAC located on an 05 Inspire daVinci, CAT C-9? How is it accessed? Has anyone seen a leaky CAC? Was it repairable?

About the CAC: is it an air-to-air cooler or air-to-water?
Anyone know where there is a plumbing diagram for the air boost system and a photo of the installed CAC?

Thanks for your help.
Jay

05 Inspire 51457

Steel radiator, 52,000 miles

Re: Access to CAC in 05 Inspire

Reply #1 –
Yahoo Message Number: 79857
there was a run of Bad CAC on some 04 and 05 CC's that I am aware of. I had reported to CC that my

midrange response was poor while at Home Coming in 05 and as they were all booked recommended I

have Cummins check out the system when I got home. Well the Cummins people removed the piping to

the CAC plugged one end and pressurized the other. And sure enough the radiator would not hold 25

lbs pressure the required time, falling about 30 seconds short. So CC sent a new CAC for replacment.

In addition they found a sensor in the turbo crossover pipe leaking, too which was replaced. When

checked the next year at CC on the Dyno I picked up 75 hp around 1600 rpm, where I cruse, and 35 hp

at 2100 rpm. So I put 360 HP on the ground at 2100 RPM which has been verified at another location.

Pretty good for an ISL 400. Usually you loose 20% through the drive line/ I don't even loose HP at home

which is 4000' elevation. I also picked up about a mpg at 60 mph. With the coach empty, I averaged

10.5 mpg on a trip to and from Chino for repairs at the Paint Department.
Full, pulling the Odessey I

average between 8.3 and 8.6 mpg, unless going over wolf creek pass in Colorado. TWI 2004 Intrigue
11731

Original Message:
-----------------

From: pelicanreef120 wjay@... Date: Sun, 03 Jun 2012 21:47:28 -0000 To: Country-Coach-Owners@yahoogroups.com Subject: [Country-Coach-Owners] Access to CAC in 05 Inspire

Greetings campers and shadetree mechanics!
I'm doing some on-the-fly troubleshooting and would appreciate some advice.
I have been experiencing an intermittent engine warning light that is brief enough to not create a

loggable event, but shows up as low boost on a CAT computer. The warning appears under heavier

than normal load, and is more frequent before the engine temps settle at normal running levels.

My air filter has been replaced and my hoses inspected. I suspect a small leak somewhere, possibly the
charge air cooler.

Where is the CAC located on an 05 Inspire daVinci, CAT C-9? How is it accessed? Has anyone seen a
leaky CAC? Was it repairable?

About the CAC: is it an air-to-air cooler or air-to-water?
Anyone know where there is a plumbing diagram for the air boost system and a photo of the installed
CAC?

Thanks for your help.
Jay

05 Inspire 51457

Steel radiator, 52,000 miles

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Re: Access to CAC in 05 Inspire

Reply #2 –
Yahoo Message Number: 79860
The charge air cooler is and air to air heat transfer device located between the air conditioning condenser and the radiator in the cooling stack on the drivers side of the Inspire. The CAC cools the air coming out of the turbo prior to it's entry to the intake manifold. The plumbing is fairly simple, utilizing large diameter tubing and hose connection boots. It is my understanding that there has been some issues with leaking CACs on Inspires, so far mine is OK. It is normal diagnostic practice to pressure test the CAC to determine if it will hold static pressure over time.
There is a CAT service bulletin that addresses low boost pressure. The bulletin requires an update to the ECM software. I recently had it applied to my coach and was covered by warranty even though the period is long expired. In my opinion, it would be a good idea to contact CAT to see if the bulletin applies to your unit.

Good luck,

Dale C.

05 Inspire 51477

Re: Access to CAC in 05 Inspire

Reply #3 –
Yahoo Message Number: 79895
We had our CAC replaced when we replaced our radiator on our 2006 inspire. Oregon Motor Coach said it was a very common failure item and they usually replace them both at the same time. Great service very large bill.

Brian O'Day

2006 Inspire #51565
2011 Escape Hybrid Toad
Portland Oregon

Re: CAT Hotline - Was CAC Access

Reply #4 –
Yahoo Message Number: 79897
Taking Dale Collier's suggestion, I called the CAT RV Hotline. Very interesting.
First off, a real human being answered within seconds. He specializes in RV applications.
Given my engine number, CAT was able to provide more info than the mech at a CAT service facility in Virginia was able to retrieve (for whatever reason).
My suspected low boost pressure condition led me to search for air leaks, following an unnecessary air filter change. (In all fairness, the filter was close to needing changeout - no harm there.)
To the contrary, the code was for high boost pressure, which means either a bad sensor or a sticky waste gate on the turbo. In either case, I'm good to complete the voyage and deliver it to my local CAT guys. "Keep an eye on it and press on."
The general reminder I received from CAT was don't disregard signals you don't like from the engine. CAT is a phone call away. I am out of warranty - - no difference.

Thanks to all for your tips.
Jay

05 Inspire 51457 C9

Re: CAT Hotline - Was CAC Access

Reply #5 –
Yahoo Message Number: 79908
Jay;

Is there an 800 number for the CAT RV Hotline? Would be good to have on file.

Thanks,
Dave Glen

'06 Magna 6591

Re: CAT Hotline - Was CAC Access

Reply #6 –
Yahoo Message Number: 79909
Dave,

I think I've used it. I think it's 1-800-BEN-DOVR.
Kevin Burns

2000 Affinity #5865

Re: CAT Hotline - Was CAC Access

Reply #7 –
Yahoo Message Number: 79910
As a retired Cat service tech I will be the first to tell you how many techs me included over look a waste gate valve on a turbo. Glad you bought this up! Ken 99 Allure 30356

Re: CAT Hotline - Was CAC Access

Reply #8 –
Yahoo Message Number: 79917
(877) 777-3126 is the RV hotline.

Kevin, it sounds like you had a less-than-satisfactory experience...?

Re: CAT Hotline - Was CAC Access

Reply #9 –
Yahoo Message Number: 79925
Jay,

You are correct. Asked them for a estimate and told them not to start any work until approval. They crashed my coach pulling it into the bay doing $5300 in damages. Then thet took my MH apart and told me I would have to pay them to put it back together. They gave me $5625 quote to repair it complete with parts. I supplied approx. $650 worth of the parts and they had it for 4 month during the summer and fall months then told me it was finished and charged me over $8300 to get it off of their lot. A hundred miles later my hydraulic motor for my fan started leaking and the hydraulic lines were melted because they layed them on the exhaust pipe. Would not come out to look at it with there mobile trucks without me paying for it because it was over 30 days. I was told I had a year warranty because I questioned them about it because I wasn't even going to be able to use it because they had knocked off my steps and busted the fiberglass around them. 1-800-ben-dovr.
Kevin Burns

2000 Affinity #5865

Re: CAT Hotline - Was CAC Access

Reply #10 –
Yahoo Message Number: 79955
Dave

I have used the hot line a number of times and they have been very accommodating. Once I was in Death Valley and a warning line came on and they talked me through a number of questions and determined that it was safe for me to continue and told me what to keep an eye out for that would indicate a more serious issue.

Dan 2006 Allure 31348