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December 16, 2022 NHTSA CAMPAIGN NUMBER: 22V934000
High Voltage Battery Packs May Fail
A sudden loss of traction power while driving increases the risk of a crash.
NHTSA Campaign Number: 22V934
Manufacturer Lightning eMotors Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 27
Summary
Lightning eMotors Inc. (Lightning eMotors) is recalling certain 2021-2022 FE4-129 vehicles equipped with Romeo Power battery packs. The high voltage battery may lose traction power while driving or fail to start.
Remedy
LeM will replace the battery, free of charge. Owner notification letters were mailed February 6, 2023. Owners may contact LeM customer service at 1-970-744-4926 or 1-800-223-0740. LeM’s number for this recall is LeM Recall 2022-002.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Chronology :
10/21/2022: Due to an observation of a high number of field failures requiring battery pack replacements, an investigation was commenced; vehicles at factory and in production were placed on Quality Hold pending the investigation.
11/09/2022: LeM’s technical teams escalated the issue to LeM legal and compliance team for evaluation.
12/09/2022: Lightning eMotors Recall Committee met. Based upon the results of the investigation, a safety defect determination was made.
There have been no reports of accidents or injuries related to this condition. There were 14 warranty claims involving replacement of Romeo batteries from December 2021 through November 2022.
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
LIGHTNING EMOTORS | FE4 | 2021-2022 |
7 Associated Documents
Defect Notice 573 Report
RCLRPT-22V934-1166.PDF 214.727KB
Recall Acknowledgement
RCAK-22V934-7137.pdf 645.515KB
Owner Notification Letter(Part 577)
RCONL-22V934-0432.pdf 273.255KB
Recall Quarterly Report #1, 2023-1
RCLQRT-22V934-1333.PDF 211.136KB
Recall Quarterly Report #2, 2023-2
RCLQRT-22V934-4693.PDF 211.237KB
Recall 573 Report-Amendment 1 – 07/04/2023
RCLRPT-22V934-8356.PDF 214.75KB
Recall Quarterly Report #3, 2023-3
RCLQRT-22V934-7978.PDF 211.453KB
Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V934&docType=RCL
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SEOCONTENT-START
OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-934 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lightning eMotors Inc. Submission Date : DEC 16, 2022 NHTSA Recall No. : 22V-934 Manufacturer Recall No. : LeM Recall 2022-002 Manufacturer Information : Manufacturer Name : Lightning eMotors Inc. Address : 815 14th Street SW Suite A100 Loveland CO 80537 Company phone : (970)744-7241 Population : Number of potentially involved : 27 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Lightning eMotors FE4-129 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : All Lightning eMotors FE4-129 vehicles equipped with Romeo Power battery packs are included in this recall. FE4-129 vehicles equipped with eMatrix battery packs are not part of the recall. Lightning eMotors/FE4-129 Qty 27 Production Dates : JAN 01, 2021 – OCT 21, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Due to multiple software and hardware discrepancies internal to the Romeo Power battery packs installed in certain Lightning eMotors (LeM) FE4-129 series vehicles, the vehicle may fail to operate in cold temperatures, fail to start when the key is placed on, or may lose traction power while driving. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A loss of traction power while driving may increase the risk of a crash. Description of the Cause : Lighting eMotors has identified that there are multiple faults internal to the Romeo Power 30.6 kWh Battery Packs installed on the subject vehicles. These include: 1) Flood Sensor fault 2) HVIL fault 3) Cell Imbalance fault Part 573 Safety Recall Report 22V-934 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 4) Low Temp (0 degrees C) sensor These faults result in potential for the vehicle to be rendered inoperative in both the start-up condition and while in normal operation. Both real and false positive sensor faults cause the battery contactors to open to prevent internal battery pack damage, preventing traction power from being available to the driver. Identification of Any Warning that can Occur : 1) Malfunction Indicator Lamp (MiL) telltale illuminates in either steady or flashing mode 2) Wrench Light telltale illuminates 3) Sudden loss of indicated State of Charge (SOC)/Range Remaining on driver displays 4) Vehicle fails to operate in temperatures below 32 degrees Fahrenheit 5) Vehicle fails to operate at any temperature Involved Components : Component Name 1 : Traction Battery; Romeo Power Component Description : Orion Pack A-C6; 30.6 kWh Component Part Number : P00016247 (LeM 811-021) Supplier Identification : Component Manufacturer Name : Romeo Power, Inc. Address : 5569 Katella Ave Cypress California 90630 Country : United States Chronology : 10/21/2022: Due to an observation of a high number of field failures requiring battery pack replacements, an investigation was commenced; vehicles at factory and in production were placed on Quality Hold pending the investigation. 11/09/2022: LeM’s technical teams escalated the issue to LeM legal and compliance team for evaluation. 12/09/2022: Lightning eMotors Recall Committee met. Based upon the results of the investigation, a safety defect determination was made. Part 573 Safety Recall Report 22V-934 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 There have been no reports of accidents or injuries related to this condition. Description of Remedy : Description of Remedy Program : The remedy is currently under development. Owner notification letters are expected to be mailed no later than February 14, 2023. Owners may contact Lightning eMotors customer service at +1(970) 744-4926 or (800) 223-0740. LeM will notify vehicle owners of the noncompliance and arrangements will be made to update their vehicles free of charge. Pursuant to 49 CFR 577.11(e), LeM requests that it be exempt from providing notification of a reimbursement plan. Any pre-notification product failure would have been replaced under the manufacturer’s limited warranty. Accordingly, no person would be eligible for reimbursement pursuant to 573.13. How Remedy Component Differs from Recalled Component : A remedy component has not been identified at this time. It is anticipated that the remedy component will be issued a revised LeM Part Number to distinguish it from a recalled component. Identify How/When Recall Condition was Corrected in Production : The correction to the recall condition has not yet been determined. The condition is internal to the Romeo Power battery packs. Vehicles currently in production have been placed on Quality Hold, awaiting a remedy from the battery supplier. Romeo Power has been formally notified of this event. Lightning eMotors is awaiting a response and remedy plan. Recall Schedule : Description of Recall Schedule : There are no affected dealers, so LeM will not be issuing a dealer notification. Accordingly, there is no “Dealer Notification” schedule. Owners will be notified in accordance with the “Planned Owner Notification” dates. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : FEB 14, 2023 – FEB 14, 2023 * NR – Not Reported
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815 14th St SW, Suite A100 Loveland, CO 80537, USA 800.223.0740 lightningemotors.com info@lightningemotors.com IR@lightningemotors.com *** IMPORTANT SAFETY RECALL *** NHTSA Recall No. 22V-934 This notice applies to your vehicle: LeM Model Bus Model Vehicle Identification Number (VIN) FE4-129 E-450 1FD 1FD 1FD 1FD 1FD 1FD 1FD 1FD February 6, 2023 Dear Lightning eMotors Customer: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Lightning eMotors. Inc. (LeM) has decided that a defect which relates to motor vehicle safety exists in certain 2021-2022 FE4-129 model vehicles equipped with Romeo Power battery packs. LeM is conducting a recall to address the condition. This action involves vehicles in which LeM powertrains were installed from January 1, 2021, through October 21, 2022, and which use Romeo Power battery packs. Our records indicate that your vehicle(s) listed above may be affected. What is the Problem? Due to multiple software and hardware discrepancies internal to the Romeo Power battery packs installed with these powertrains, the vehicle may fail to operate in cold temperatures, fail to start when the key is placed on, or may lose traction power while driving. A loss of traction power without warning while driving may increase the risk of a crash. O.►, LIGHTNING ~_, e MOT O R S ‘~<:).,, LIGHTNING e M O T O R S What Are We Doing About the Problem? Page2 LeM will replace the Romeo batte1y with a non-defective batte1y , free of charge. If a replacement batte1y is unavailable, LeM will discuss alternative remedy options with you. Please contact LeM at support@lightningemotors.com or 970-744-4926 for more infonnation. If you no longer own the vehicle( s) listed above, please f 01ward this notice to the new owner and provide the new owner ‘s address to us at support@lightningemotors.com. Federal law requires vehicle lessors receiving this recall notice to fo1ward a copy to the lessee within ten days. Also, it is a violation of Federal law for a dealer to deliver a new vehicle covered by this recall notice under a sale or lease until the noncompliance has been remedied. Questions or Concerns? If you have questions or concerns about this recall, please contact us at support@lightningemotors.com or 970-744-4926. If you are unable to obtain a remedy without charge within a reasonable time, you may submit a complaint to: Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. We are talcing this action in the interest of your safety and satisfaction with our products. We apologize for any inconvenience and thank you for your attention to this matter. Sincerely, Troy Mai VP Quality Enclosures: 1. LeM Pali 573 Defect Notification 815 14th St SW, Suite A100 Loveland, CO 80537, USA Telephone: 1.800.223.07 40 lightningemotors.com
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-934 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lightning eMotors Inc. Submission Date : JUL 04, 2023 NHTSA Recall No. : 22V-934 Manufacturer Recall No. : LeM Recall 2022-002 Manufacturer Information : Manufacturer Name : Lightning eMotors Inc. Address : 815 14th Street SW Suite A100 Loveland CO 80537 Company phone : (970)744-7241 Population : Number of potentially involved : 27 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Lightning eMotors FE4-129 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : All Lightning eMotors FE4-129 vehicles equipped with Romeo Power battery packs are included in this recall. FE4-129 vehicles equipped with eMatrix battery packs are not part of the recall. Lightning eMotors/FE4-129 Qty 27 Production Dates : JAN 01, 2021 – OCT 21, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Due to multiple software and hardware discrepancies internal to the Romeo Power battery packs installed in certain Lightning eMotors (LeM) FE4-129 series vehicles, the vehicle may fail to operate in cold temperatures, fail to start when the key is placed on, or may lose traction power while driving. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A loss of traction power while driving may increase the risk of a crash. Description of the Cause : Lighting eMotors has identified that there are multiple faults internal to the Romeo Power 30.6 kWh Battery Packs installed on the subject vehicles. These include: 1) Flood Sensor fault 2) HVIL fault 3) Cell Imbalance fault Part 573 Safety Recall Report 22V-934 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 4) Low Temp (0 degrees C) sensor These faults result in potential for the vehicle to be rendered inoperative in both the start-up condition and while in normal operation. Both real and false positive sensor faults cause the battery contactors to open to prevent internal battery pack damage, preventing traction power from being available to the driver. Identification of Any Warning that can Occur : 1) Malfunction Indicator Lamp (MiL) telltale illuminates in either steady or flashing mode 2) Wrench Light telltale illuminates 3) Sudden loss of indicated State of Charge (SOC)/Range Remaining on driver displays 4) Vehicle fails to operate in temperatures below 32 degrees Fahrenheit 5) Vehicle fails to operate at any temperature Involved Components : Component Name 1 : Traction Battery; Romeo Power Component Description : Orion Pack A-C6; 30.6 kWh Component Part Number : P00016247 (LeM 811-021) Supplier Identification : Component Manufacturer Name : Romeo Power, Inc. Address : 5569 Katella Ave Cypress California 90630 Country : United States Chronology : 10/21/2022: Due to an observation of a high number of field failures requiring battery pack replacements, an investigation was commenced; vehicles at factory and in production were placed on Quality Hold pending the investigation. 11/09/2022: LeM’s technical teams escalated the issue to LeM legal and compliance team for evaluation. 12/09/2022: Lightning eMotors Recall Committee met. Based upon the results of the investigation, a safety defect determination was made. Part 573 Safety Recall Report 22V-934 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 There have been no reports of accidents or injuries related to this condition. There were 14 warranty claims involving replacement of Romeo batteries from December 2021 through November 2022. Description of Remedy : Description of Remedy Program : The remedy is currently under development. Owner notification letters are expected to be mailed no later than February 14, 2023. Owners may contact Lightning eMotors customer service at +1(970) 744-4926 or (800) 223-0740. LeM will notify vehicle owners of the noncompliance and arrangements will be made to update their vehicles free of charge. Pursuant to 49 CFR 577.11(e), LeM requests that it be exempt from providing notification of a reimbursement plan. Any pre-notification product failure would have been replaced under the manufacturer’s limited warranty. Accordingly, no person would be eligible for reimbursement pursuant to 573.13. How Remedy Component Differs from Recalled Component : LeM will replace the Romeo battery with a non-defective battery, free of charge. If a replacement battery is unavailable, LeM will discuss alternative remedy options with you. Identify How/When Recall Condition was Corrected in Production : The condition is internal to the Romeo Power battery packs. Vehicles currently in production have been placed on Quality Hold, awaiting a remedy from the battery supplier. Romeo Power has been formally notified of this event. Lightning eMotors is awaiting a response and remedy plan. Recall Schedule : Description of Recall Schedule : There are no affected dealers, so LeM will not be issuing a dealer notification. Accordingly, there is no “Dealer Notification” schedule. Owners will be notified in accordance with the “Planned Owner Notification” dates. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : FEB 14, 2023 – FEB 14, 2023 * NR – Not Reported
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