Country Coach Owners Forum Country Coach Motorcoach Forum

Hi Ray,

CCI must have located sensors in different locations. On coach

there is no electrical sensor before the turbo for fresh air - only > the air line to the filter indicator. There is what appears to be a > single blue wire leading to a sensor on the high pressure side in

horizontal pipe about 14 inches before it goes vertical into the > intake manifold.
Fred Kovol

200 Allure 30593

[quote author=travman100"

>

> Just wanted to pass on the latest in my efforts to get a properly > > functioning cooling fan. Mine runs in default mode, High Speed.
>

> CC has attempted the following fixes: > >

> Checked all components in the hydraulic and electrical portions

the system.
>

> This resulted in the replacement of air sensor on two ocassions,

reprogramming of the fan controller, and finally the replacement

the fan controller. It actually appeared to work for a few days

the fan controller was replaced and the dust storm > > disappeared....unfortunately, three days after replacement of the > > fan controller I was heading out of the coastal area of Oregon

the small mountains toward Portland when the engine coolant high > > temp light came on. I called tech support and they instructed me

disconnect the 6 wire connector to the fan controller. Bingo, it > > defaulted to high speed and I left it there so my new fan

was now working like the old fan controller.
>

> I recently took the coach to a Cummins center where a factory

engineer took it on himself to try and solve the fan issue, he

tried to see if it was tied into the Cummins ECM, some of the CC > > wiring diagrams indicate that it is connected and other diagrams > > show no connection at the fan control output of the ECM. We

CC to get the real story, CC told the Cummins engineer that they > > didn't use the ECM fan controller signals at all. They use the > > coolant temp sensor, the inlet turbo side air duct sensor and a > > signal from the chassis AC system. Armed with this knowledge the > > Cummins engineer isolated the problem to the air duct sensor, he > > pulled the sensor and found that it had water residue on it and

it was open, as you may know the sensor is installed upside down

the bottom of the air duct thus catching any condensation which > > might wind up in the air duct causing the failure, in his

He then used a variable resistor in place of the sensor and was

to control the speed of the fan by rotating the variable resistor > > control through it's range. This seems to verify that the fan > > controller and related fan control components are working.
>

> I would like to know if anyone else has attempted to solve their

problems by having the air duct modified by a machine shop and

the sensor to the top side of the air duct, this would require a

snub to be installed in the top side and the bottom half to be > > plugged. The cummins engineer thinks this would be best fix for

problem since he says that failures from moisture collecting in

duct would then fall away from the sensor element thus decreasing > > the likelyhood of failure due to moisture collecting on the

element.
>

> This sounds like a potential fix to the problem....next question

how many units were made with the sensor mounted in the bottom

of the air duct rather than on the top side? Was this the

way and is it still done that way. This might explain the high > > number of failures of the fan resulting in high fan speed, lost

Fred,

It is possible that the Allure and the Intrigue were wired > differently for the fan controller. To try and clarify the position > of the air sensor in the ductwork....if you were to remove the

cover under the bed and look to left side of engine, I see a > horizontal section of the air duct coming from the air filter side.
The air sensor (Airpax part number I believe) is located about > halfway down the run of that horizontal pipe...mine is located on

bottom side of the duct and it has a gray connector running to it.
The sensor appears to be made of brass.

I'll check to see if I can copy the portion of the wiring diagram > which shows the NC on the ECM fan control outputs. The Cummins > engineer used the diagrams provided with my coach to try to

if the ECM was involved before I called CC and talked to "Herb" in > tech support. I then gave the phone to the Cummins engineer who

to Herb and Herb told him that CC does not use the ECM at all for

cooling fan controller inputs. He went on to say that it used the > coolant temp sensor, the air duct sensor and a signal from the AC > unit. I think the troubleshooting sheet available in the Files > section here in our group files shows wire 300 goes to a relay in

passenger side dash area. Believe that is the only connection

the engine compartment for the fan controller inputs.

My coach is still at the Cummins service center now, Cummins sent > three field engineers to try and solve the black smoke issue which I > have had on the coach since it was purchased new a little over 5 > years ago. I was fortunate enough to get attention of the

side of Cummins and they want to help solve that problem. They have > been great in their approach and very thorough. While they were > troubleshooting the smoke problem, they said to me, "your coolant

is running at a high rate of speed," and it 25 degrees outside. I > told them that it had always run that way so they immediately said

need to check the ECM fan controller signal to see if it is > functioning properly. I told them I thought it was not using their > signal, and that is how we got the CC tech involved and that was the > extent of his involvment. The field engineer basically traced the 6 > wire connections and that is how he found the suspect air sensor in > the turbo duct system. He pulled the sensor which was covered with > rust. He also recommended that I have a machine shop make the > previously mentioned modification to avoid the moisture accumulation > problem. I am hoping to get this information to the right person at > CC to see if they can give me advice on the modification....maybe > even help me with the cost of the modification....hmmm.
> I'll get back to you with the wiring diagram...assuming I am able to > make copies that can be posted, I will also put them in the file or > photo section depending on my success at copying them.

Ray

2000 Intrigue 11040

[quote author=fredkovol"

>

> Hi Ray,

> CCI must have located sensors in different locations. On coach > 30593,

> there is no electrical sensor before the turbo for fresh air -

the air line to the filter indicator. There is what appears to be

single blue wire leading to a sensor on the high pressure side in > the

> horizontal pipe about 14 inches before it goes vertical into the > > intake manifold.
> Fred Kovol

> 200 Allure 30593
>
>

[quote author=travman100"
>]
> >

> > Just wanted to pass on the latest in my efforts to get a

> functioning cooling fan. Mine runs in default mode, High Speed.
> >

> > CC has attempted the following fixes: > > >

> > Checked all components in the hydraulic and electrical portions > of

> > the system.
> >

> > This resulted in the replacement of air sensor on two ocassions, > the

> > reprogramming of the fan controller, and finally the replacement > of

> > the fan controller. It actually appeared to work for a few days > when

> > the fan controller was replaced and the dust storm > > > disappeared....unfortunately, three days after replacement of

> fan controller I was heading out of the coastal area of Oregon > over

> > the small mountains toward Portland when the engine coolant high > > > temp light came on. I called tech support and they instructed me > to

> > disconnect the 6 wire connector to the fan controller. Bingo, it > > > defaulted to high speed and I left it there so my new fan > controller

> > was now working like the old fan controller.
> >

> > I recently took the coach to a Cummins center where a factory > field

> > engineer took it on himself to try and solve the fan issue, he > first

> > tried to see if it was tied into the Cummins ECM, some of the CC > > > wiring diagrams indicate that it is connected and other diagrams > > > show no connection at the fan control output of the ECM. We > called

> > CC to get the real story, CC told the Cummins engineer that they > > > didn't use the ECM fan controller signals at all. They use the > > > coolant temp sensor, the inlet turbo side air duct sensor and a > > > signal from the chassis AC system. Armed with this knowledge the > > > Cummins engineer isolated the problem to the air duct sensor, he > > > pulled the sensor and found that it had water residue on it and > said

> > it was open, as you may know the sensor is installed upside down > in

> > the bottom of the air duct thus catching any condensation which > > > might wind up in the air duct causing the failure, in his > opinion.

> > He then used a variable resistor in place of the sensor and was > able

> > to control the speed of the fan by rotating the variable

> control through it's range. This seems to verify that the fan > > > controller and related fan control components are working.
> >

> > I would like to know if anyone else has attempted to solve their > fan

> > problems by having the air duct modified by a machine shop and > move

> > the sensor to the top side of the air duct, this would require a > new

> > snub to be installed in the top side and the bottom half to be > > > plugged. The cummins engineer thinks this would be best fix for > the

> > problem since he says that failures from moisture collecting in > air

> > duct would then fall away from the sensor element thus

Just wanted to pass on the latest in my efforts to get a properly > functioning cooling fan. Mine runs in default mode, High Speed.

CC has attempted the following fixes: >

Checked all components in the hydraulic and electrical portions of > the system.

This resulted in the replacement of air sensor on two ocassions,

reprogramming of the fan controller, and finally the replacement of > the fan controller. It actually appeared to work for a few days

the fan controller was replaced and the dust storm > disappeared....unfortunately, three days after replacement of the > fan controller I was heading out of the coastal area of Oregon over > the small mountains toward Portland when the engine coolant high > temp light came on. I called tech support and they instructed me to > disconnect the 6 wire connector to the fan controller. Bingo, it > defaulted to high speed and I left it there so my new fan

was now working like the old fan controller.
> I recently took the coach to a Cummins center where a factory field > engineer took it on himself to try and solve the fan issue, he

tried to see if it was tied into the Cummins ECM, some of the CC > wiring diagrams indicate that it is connected and other diagrams > show no connection at the fan control output of the ECM. We called > CC to get the real story, CC told the Cummins engineer that they > didn't use the ECM fan controller signals at all. They use the > coolant temp sensor, the inlet turbo side air duct sensor and a > signal from the chassis AC system. Armed with this knowledge the > Cummins engineer isolated the problem to the air duct sensor, he > pulled the sensor and found that it had water residue on it and

it was open, as you may know the sensor is installed upside down in > the bottom of the air duct thus catching any condensation which > might wind up in the air duct causing the failure, in his opinion.
He then used a variable resistor in place of the sensor and was

to control the speed of the fan by rotating the variable resistor > control through it's range. This seems to verify that the fan > controller and related fan control components are working.

I would like to know if anyone else has attempted to solve their

problems by having the air duct modified by a machine shop and move > the sensor to the top side of the air duct, this would require a

>

Ray, Hi, I finally got my FCM working perfect last March at FMCA.

was having your same problem. The super expert at CC is Steve

But maybe hard to get too, the Tech that is real good on the FCM

Russ.

Just this last week mine began to act up again. Normally without

on I run 191/193 degrees up to 201/203 degrees then fan comes on.

well I had Steve SToney program my low temp RPM real low so I > wouldn't throw dust.

This week mine has freaked out and is now running 178 degrees to

degrees. But might all of sudden start functioning properly, but

consistant. Not good. I called Russ last night.

He says to pull the 6 pin connector apart at the FCM, check the

for corrosion, push the wires in tightly to the connector.

the FCM is in a naturally dirty area. He said to put some Di-

Grease before reconnecting. Since mine runs correctly part of the > time he believes the FCM has not de-programed.

Re: my Air Temp Sensor its located in the MIDDLE of the Horizontal > Pipe (Duct).

If the Connector pins/wires or OK, Russ says to check both the Air > and Coolant Sensors to see if there both functioning.

Thanks, MIke Carnes - 2003 Allure 1st Ave. #30898 >

[quote author=travman100"

>

> Just wanted to pass on the latest in my efforts to get a

functioning cooling fan. Mine runs in default mode, High Speed.
>

> CC has attempted the following fixes: > >

> Checked all components in the hydraulic and electrical portions

the system.
>

> This resulted in the replacement of air sensor on two ocassions, > the

> reprogramming of the fan controller, and finally the replacement

the fan controller. It actually appeared to work for a few days > when

> the fan controller was replaced and the dust storm > > disappeared....unfortunately, three days after replacement of

fan controller I was heading out of the coastal area of Oregon

the small mountains toward Portland when the engine coolant high > > temp light came on. I called tech support and they instructed me

disconnect the 6 wire connector to the fan controller. Bingo, it > > defaulted to high speed and I left it there so my new fan > controller

> was now working like the old fan controller.
>

> I recently took the coach to a Cummins center where a factory

engineer took it on himself to try and solve the fan issue, he > first

> tried to see if it was tied into the Cummins ECM, some of the CC > > wiring diagrams indicate that it is connected and other diagrams > > show no connection at the fan control output of the ECM. We

CC to get the real story, CC told the Cummins engineer that they > > didn't use the ECM fan controller signals at all. They use the > > coolant temp sensor, the inlet turbo side air duct sensor and a > > signal from the chassis AC system. Armed with this knowledge the > > Cummins engineer isolated the problem to the air duct sensor, he > > pulled the sensor and found that it had water residue on it and > said

> it was open, as you may know the sensor is installed upside down

the bottom of the air duct thus catching any condensation which > > might wind up in the air duct causing the failure, in his

He then used a variable resistor in place of the sensor and was > able

> to control the speed of the fan by rotating the variable

control through it's range. This seems to verify that the fan > > controller and related fan control components are working.
>

> I would like to know if anyone else has attempted to solve their > fan

> problems by having the air duct modified by a machine shop and

the sensor to the top side of the air duct, this would require a > new

> snub to be installed in the top side and the bottom half to be > > plugged. The cummins engineer thinks this would be best fix for

problem since he says that failures from moisture collecting in

duct would then fall away from the sensor element thus

the likelyhood of failure due to moisture collecting on the

element.
>

> This sounds like a potential fix to the problem....next question

how many units were made with the sensor mounted in the bottom

of the air duct rather than on the top side? Was this the

way and is it still done that way. This might explain the high > > number of failures of the fan resulting in high fan speed, lost