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sscarp · 08-21-2012, 06:17 AM

My RV is going back to Thor. They are arranging to bring it back to the factory to inspect it. After wasting my time with the vented door and fuel line heat shield, they now tell me that is not what is really needed. Rather they need to put the heat shield 'box' around the entire unit.

This should be interesting. I am still in contact with an attorney. This will be the last shot they get. I am going to have them put in righting that this case will not be closed till for at least 12 months, as I will not be using the RV in the 90 deg temps again till next year. I live in Ohio and will only be using it now for tailgating in cooler weather.

Towertime · 08-21-2012, 02:38 PM

Well, I took my coach into CW today and they installed the heat shield on the back side of the generator and the fuel line wrap back near the engine exhaust. The installation looks like the pictures Moonshine94 posted....CW also had to call Thor to find out how to install them. Based on sscarp's experience with these two mods (and a vented door) I don't have much confidence that this will work. Like everyone else, I am not too likely to get into the conditions that caused the problem again until probably next summer. Hopefully, Thor will come to their senses by then and issue a recall for this awful design.

Moonshine94 · 08-22-2012, 05:25 AM

It'll likely be next summer before mine sees similar conditions, but I think Thor owns this issue until it's been resolved. The issue is temp related, it's been reported to them under warranty, so I think they're on the hook if their fix doesn't work and we don't discover that until after the warranty has expired.

sanfordturbo · 08-23-2012, 10:22 AM

Finished up my heat shield for the NASCAR Bristol race.

Here is the frame around the generator. I thought I would be able to put some sheet metal around it to create a box, but the frame they use and the bracing around it, made it difficult to do.

I bought a bunch of Dynamat from BestBuy. Total was less than $200.

The stuff was really sticky. Just peel the back off of it and slap it on. I used some sheers to cut the stuff into manageable pieces. If you try to use too big a section, it will stick to stuff and make it a big pain to adhere.

I wish I had spent more time building the sheet metal box around the unit, but I am very pleased with the results. I don't have a dB meter, so I can't tell you the exact reduction in noise, but it is noticeable quieter than before. Especially in the coach. I bought a Genturi stack for the exhaust too. It cuts down on the noise a bit too. I was surprised that the exhaust tip put out so much noise.

Drove through the smokey mountains with the generator running the whole time with the A/C blasting. It never quit running.

We've been camping for a few days now with the generator running. It has not stopped at all.

When I wrapped the generator with Dynamat, I went all the way to the top. The heat is trapped above the unit . . except that my mesh door modifications allow it all to spill out of the door. If I put my hand next to the mesh door, I can feel heat pouring out of the top and side. The right side of the generator has the exhaust housing. it is the biggest heat source. It is very hot on the right side of the mesh door. right where the foam door started to bubble out and warp. since the mesh door is so big, the exhaust housing heat pours out immediately and does not get a chance to recirculate back into the generator.

I consider the problem solved. heat shield wrap and noise reduction, modified mesh door. that's all I did. Thor should give this a try.

sanfordturbo · 08-23-2012, 12:22 PM

Oh yeah... I also topped off the oil, (changed it) and changed the spark plug.

bdickson · 08-23-2012, 05:52 PM

I have a (maybe dumb) question: Does the Code 36 shutdown occur only when running the generator while driving? We've never run the gen while moving, since there are only two of us and the dash air plus 2 fans I installed keeps us cool enough. In fact, I really only run the gen once a month for 30 minutes to exercise it.

Towertime · 08-24-2012, 02:46 AM

Quote:

Originally Posted by bdickson

I have a (maybe dumb) question: Does the Code 36 shutdown occur only when running the generator while driving? We've never run the gen while moving, since there are only two of us and the dash air plus 2 fans I installed keeps us cool enough. In fact, I really only run the gen once a month for 30 minutes to exercise it.

I think most everyboday that has seen this shutdown condition has seen it while driving with pretty high outside temperatures. It is probably less likely to happen while you are parked since you wouldn't necessarily have the extra heat coming off the engine/transmission and exhaust system of the coach. The times I have had the unit shutdown, it was at least upper 90's, sometimes 100 plus outside and I had been driving for at least a couple of hours. I have run the generator with the coach parked with mid-90's outside for as long as 7 hours and have not had a shutdown.

Moonshine94 · 08-24-2012, 11:24 PM

+1 on what Towertime said. Mine has run for 8+ hours in 95-100 degree temps with the coach parked without problem. But run the coach engine + genset in high temps and after a few hours the genset dies, showing the Code 36.

DegoRed · 08-26-2012, 02:55 PM

Here is a picture of mine with the sheet metal back. I bought a 31"x19" piece, cost $15. It covers the entire back of the generator. I unbolted the black cross bar piece so the piece of sheet metal sits flat. Drilled 6 holes in the sheet metal so I could use the existing bolt hole locations.

Only hiccup was that the existing bolt that go through the black cross bar piece were too short, so had to run to home depot to get some longer bolts, these are 1" bolts with star lock washers.

Also went ahead and put the bent angle piece that Thor sent me on, figured since I already had it, might as well us it. Put it on top of the flat piece of sheet metal that I used.

Did not put the fuel line heat shield on yet, since I am going to take the generator to CW to have them look at it, figured they could fight with the fuel line.

Still thinking about the oil cooler, will let you know if I figure something out on this front.

DegoRed · 09-03-2012, 02:49 PM

Drove 4 hours each way to the coast this weekend. On the way down, outside temps weren't bad, low 90's entire way. On way home it was smoking, temps were over 100 the entire way home.

Generator never shut down once either way. Flogged the motor/trans pretty good on the way home trying to simulate some long grades, but generator never shut off.

Keep in mind, I have not installed the fuel line heat wrap ( not really even sure what good this does anyway). So covering my generator top to bottom with a full piece of sheet metal seems to have worked at least for this trip.

Not sure what this means if anything at all, but kids were happy in back playing XBox and watching movies, so guess its a small victory for now.

Moonshine94 · 09-04-2012, 04:56 AM

Thanks for the update and glad you seem to have yours fixed.

Davinger · 09-05-2012, 05:24 AM

Quote:

Originally Posted by bdickson

I have a (maybe dumb) question: Does the Code 36 shutdown occur only when running the generator while driving? We've never run the gen while moving, since there are only two of us and the dash air plus 2 fans I installed keeps us cool enough. In fact, I really only run the gen once a month for 30 minutes to exercise it.

I did a check that you may want to look into. I ran my coach for 8 hours on the dash AC and 8 hours on the top ac while driving. The difference was 2MPG better with the top ac. However if the temperature is really hot the Dash for driving is the only way to go.

Towertime · 09-19-2012, 07:26 PM

Quote:

Originally Posted by sscarp

My RV is going back to Thor. They are arranging to bring it back to the factory to inspect it. After wasting my time with the vented door and fuel line heat shield, they now tell me that is not what is really needed. Rather they need to put the heat shield 'box' around the entire unit.

This should be interesting. I am still in contact with an attorney. This will be the last shot they get. I am going to have them put in righting that this case will not be closed till for at least 12 months, as I will not be using the RV in the 90 deg temps again till next year. I live in Ohio and will only be using it now for tailgating in cooler weather.

Did you get your ACE back yet? If so, I think we would all like to see what Thor did to correct the generator issue. Please post some pics of the completed work.