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Old 01-03-2017, 02:31 PM   #1
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Brand: Thor Motor Coach
Model: Challenger LX
State: Colorado
Posts: 122
THOR #3922
Onan 5500

The Onan 5500 generator in my 2016 Challenger LX has been dying after some period of running - usually around 10 minutes. Fails with a code 36. Had the Cummins authorized rep out this morning. We tested with the compartment door open (not the generator cover) and it ran for 30 minutes. After closing the compartment door the generator shut down in 5 minutes. Cummins tech-rep says it's recirculating the heat up into the front of the compartment, and there is a service bulletin on this problem. Apparently there is a kit to resolve this issue. Anyone else have this kind of problem?

Cummins guy has gone back to his shop - says he will install the kit tomorrow.
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Old 01-03-2017, 03:11 PM   #2
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Model: 37GT
State: Florida
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THOR #5246
I haven't gotten the exact code off mine yet. It will run while sitting stationary but dies within 10 minutes of highway speeds.

Interested to see what the "kit" involves that he will install.
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Old 01-03-2017, 03:47 PM   #3
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Brand: Thor Motor Coach
Model: Challenger LX
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THOR #3922
update

It's apparently some kind of aluminum ducting to divert the hot air away from the genset. However, Commins says it's a genset installation issue, so not under Cummins warranty. I'm working with the good folks at Thor to see if they will cover the part and installation.
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Old 01-04-2017, 12:08 AM   #4
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Brand: Thor Motor Coach
Model: 30.1
State: North Carolina
Posts: 326
THOR #3952
I was experiencing the same code with my Onan 4000. After much research I installed a vent in the bay door which isolates the intake air to the outside. Before it was sucking the hot air from under the coach and the engine area.The black boot fits between the door and face of the generator. I believe the intake air on the 5000 is different. I will say it was very hot outside when mine was doing this. In the 90's.
I also believe the 5500 gets its intake air from the bottom so this will not work for you. Some peolple added an extra fuel pump for this issue.
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Old 01-04-2017, 12:11 AM   #5
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THOR #3952
Finished vent
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Old 01-04-2017, 12:47 AM   #6
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THOR #3922
venting

That's a sweet looking mod. Thor is shipping me a front/rear exit duct kit. It allows the intake air to flow through the door or floor and exhaust air to flow through the compartment door. The kit is made by Cummins Onan specifically to deal with the 5500/7000. Looks like an easy install.
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Old 01-04-2017, 01:42 AM   #7
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THOR #3952
Quote:
Originally Posted by j37genie View Post
That's a sweet looking mod. Thor is shipping me a front/rear exit duct kit. It allows the intake air to flow through the door or floor and exhaust air to flow through the compartment door. The kit is made by Cummins Onan specifically to deal with the 5500/7000. Looks like an easy install.
I believe it's because of the small space these generators are mounted in, they can't breath properly. There is only 1 1/2" of space between the back of my door and front of the intake. The vent fixed it. When I called Thor, they didn't acknowledge the problem. Had the local Forest River dealer order me the vent.
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Old 01-04-2017, 02:28 PM   #8
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THOR #5246
Quote:
Originally Posted by j37genie View Post
That's a sweet looking mod. Thor is shipping me a front/rear exit duct kit. It allows the intake air to flow through the door or floor and exhaust air to flow through the compartment door. The kit is made by Cummins Onan specifically to deal with the 5500/7000. Looks like an easy install.
Is Thor charging you for the kit?
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Old 01-04-2017, 02:35 PM   #9
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THOR #3922
Thor

No - Thor is not charging me for the kit. There is an Onan service bulletin out on this, and Onan built the kit.
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Old 07-25-2019, 12:44 AM   #10
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THOR #14384
I'd love to see a picture of this kit installed.
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Old 07-25-2019, 12:58 PM   #11
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THOR #7853
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Originally Posted by apr67 View Post
I'd love to see a picture of this kit installed.
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Old 07-25-2019, 02:47 PM   #12
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Brand: Thor Motor Coach
Model: '17-Vegas 24.1
State: California
Posts: 1,055
THOR #13362
The new 2020 Vegas now includes an integrated vent in the generator door.
So obviously, there was a come to Jesus meeting between Onan and Thor about overheating.
Look for this mod on all future Thor’s
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Old 07-25-2019, 04:03 PM   #13
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Model: THOR Chateua 35SF
State: Georgia
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THOR #11130
Is the 5500 air cooled or does it have a radiator and fan?
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Old 07-25-2019, 04:25 PM   #14
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THOR #13362
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Originally Posted by The Gritz Carlton View Post
Is the 5500 air cooled or does it have a radiator and fan?
All the Onan gas generators are listed as ”Air Cooled”
All Diesel generators (except OD 3200) are listed “Liquid Cooled”
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