Electrical Short-Circuit in Fuse Box – 2022 Gillig Low Floor CNG Transit Buses

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-356 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Gillig, LLC Submission Date : MAY 18, 2023 NHTSA Recall No. : 23V-356 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Gillig, LLC Address : 451 Discovery Drive LIVERMORE CA 94551 Company phone : 1-800-735-1500 Population : Number of potentially involved : 50 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 GILLIG LOW FLOOR CNG Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : CNG/LPG Descriptive Information : Metal-to-metal contact may cause an electrical short in the vehicle fuse box. Production Dates : AUG 10, 2022 – DEC 01, 2022 VIN Range 1 : Begin : 15GGD3115N3196740 End : 15GGD3112N3196789 ✔ Not sequential Description of Defect : Description of the Defect : GILLIG has determined that a limited population of CNG vehicles is affected by a defect that may cause an electrical failure in the fuse box mounted underneath the driver’s platform. The insulation of the red 24V busbar may become compromised due to excessive preload pinching the rubber grommet between the copper busbar and the steel fuse box. The resulting electrical short may cause a thermal event thus increasing the risk of vehicle fire. As a result of the above, GILLIG has decided to voluntarily initiate a safety recall campaign for the vehicle population that may be affected by the issue. Only one customer is affected by this recall. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A thermal event with increased risk of vehicle fire Description of the Cause : NR Identification of Any Warning that can Occur : GILLIG is not aware of any driver’s warning prior to failure. Involved Components : Part 573 Safety Recall Report 23V-356 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : On April 13 2023 during manufacturing, an incomplete vehicle experienced an electrical failure in the fuse box mounted underneath the driver’s platform. Between April 14 and April 22, GILLIG conducted an internal analysis to determine the nature of the issue and whether the same event could potentially affect other vehicles. The early findings pointed towards a possible electrical short caused by contact between the 24V busbar and the metal fuse box. Meanwhile, on April 20, out of an abundance of caution, the vehicle customer identified as potentially affected, decided to ground the entire suspect fleet. On April 24 GILLIG engineering confirmed the initial observation and determined the issue may be caused by a custom redesign of the low-voltage disconnect switch which may cause excessive preload and subsequent damage of the rubber insulation grommets of the fuse box. On April 26 GILLIG completed safety analysis and confirmed the failure mode may potentially affect a limited population of vehicles owned by the customer initially identified. On May 11 the GILLIG Safety Committee decided to file a formal safety recall with NHTSA. As of May 16 2023, GILLIG is not aware of any other similar event nor injuries potentially related to this condition. Part 573 Safety Recall Report 23V-356 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : The remedy consists of a redesign of the 12 and 24V busbars that eliminates excessive pinch of the rubber grommets and ensures appropriate electrical isolation. Pursuant to 49 CFR 577.11(e), GILLIG requests that it be exempt from providing notification of a reimbursement plan. Any pre-notification product failure would have been addressed 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 : New 12V and 24V busbar parts. Identify How/When Recall Condition was Corrected in Production : All current production buses with a similar low-voltage disconnect design will be updated with the new parts. Recall Schedule : Description of Recall Schedule : GILLIG plans to send out the owner’s notification letters by the end of the 60-day period from the date this recall is filed. GILLIG does not have a dealer network and, therefore, a dealer’s notification is not required. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR * NR – Not Reported

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