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Old 07-30-2019, 02:43 PM   #1
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Location: Aguanga, CA 92536
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2019 ACE 30.3 Electrical Connection Alert!!

Had a reallly perplexing electrical issue.

One of the 110 breakers (5a) kept popping. (New ACE 30.3 less than 3k miles.)

Ok, I've had breakers pop before for some (eventually) obvious reason.

This time, the breaker would be fine for...... 15 to 20 minutes then pop. (Usually during my nap! lol)

I'd reset the thing... then.... 15-20 minutes later..... pop.

Finally, I unplugged everything on the circuit - two refrigerators, 3 tv's, dvd player - everything but the converter.

Ok.... the circuit stayed live. Hmmmm overloaded circuit, right??

So, I think, ok, I'll change some of the appliances to other circuits.

But wait... maybe it's the breaker itself.... they do go bad... so I unplug and take it apart.

I think, ok, I'll remove the breaker just for a look-see. (I'm more of a 'wire wiggler' than an automotive electrician.)

WTH??? The wire's insulation has melted!! (see photo) And just about that time, I realize why....

The wire falls out of the breaker all by itself.

An arcing wire right under my bed. Great.

Ok... so I had to go buy a new extended square drive #2 because a regular one wouldn't fit in the recess (photo).... and while I was there picked up some shrink tubing.

Fix was easy, shrink tube over the melted insulation, back together everything fine....

But.... I think... I'd better wiggle the REST of the wires....

Before I know it, I have ANOTHER wire in my hand having fallen out of the breaker. This time, it's a dry crimp wire connector not crimped correctly. (photo)

Whew, I think... so I blow all the factory debris out of the electrical panel, button things up and what do I discover??

There was a NAIL from a nail gun laying in the electrical panel amid the sawdust!! (photo)

So.... thank Goodness my new coach did not burn up.

Thought I'd pass this along to fellow 'wire wigglers'.

I'd love to hear what other's experiences have or will turn out to be with this.

Be sure to unplug first.

Lon aka woodbender
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Old 07-31-2019, 12:41 PM   #2
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Update:

After 24 hours all seems normal, no outages.
All appliances (plus coffee pot) reconnected.
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Old 07-31-2019, 04:26 PM   #3
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This is common unfortunately, if that scares you the you better not stop while you are on a roll. Next open the transfer switch box, and not just there but any connection box, they have a habit of wire nutting stranded wire to solid and especially in the transfer switch, countless posts here about people smelling something burning and it is the wire nuts that are the issue. They are loose or the stranded wire has come out most of the way overheating. It is absolutely critical to check this stuff. I replaced every wire nut I could find with terminal connections. Same with plumbing fittings, check your water heater and all connections to the faucets and also the drain connections. I love my thor but mainly because I did all of the rework to make it safe.
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Old 08-01-2019, 03:00 PM   #4
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Thanks, Knight. I'm definitely going to keep at this. I'd like to keep this rig around for a while. I really like it.

Funny that Thor isn't more vigilant about this pretty basic safety stuff.

Plumbing... hadn't thought about that project. Good thing I like to putter around.
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Old 08-01-2019, 03:02 PM   #5
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Quote:
Originally Posted by woodbender View Post
Thanks, Knight. I'm definitely going to keep at this. I'd like to keep this rig around for a while. I really like it.

Funny that Thor isn't more vigilant about this pretty basic safety stuff.

Plumbing... hadn't thought about that project. Good thing I like to putter around.
LOL, good thing you like your RV because the puttering stuff will NEVER end lol
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Old 08-07-2019, 04:30 PM   #6
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Part of my winter hibernation wake up routine is to check all the electrical connections in the breaker panel, transfer switch and shore power cord. No problems so far but I've seen a lot of posted images of charbroiled transfer switched.
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