Lift-up Cover May Unexpectedly Fall – 2012-2019 KME

April 2, 2019 NHTSA CAMPAIGN NUMBER: 19V267000

Lift-up Cover May Unexpectedly Fall

If the lock is not engaged, the sliding, lift-up cover may fall unexpectedly, increasing the risk of injury to personnel working under the cover.

Kovatch Mobile Equipment Corp. (KME) is recalling certain 2017 Commercial Rescue, 2014-2019 Predator Panther Pumper, Commercial Pumper and Predator SS Pumper, 2012-2019 Predator Pumper, 2015-2019 Commercial Wildland, 2018 Predator Rescue and 2016 Predator SS Wildland vehicles. The lock for the gas springs that support the sliding, lift-up cover may be unintentionally disabled, preventing the lock from engaging.

 

Remedy

KME will notify owners, and dealers will replace the gas springs on the sliding, lift-up cover with new gas springs with an alternative locking mechanism or new gas springs without a locking mechanism and a separate stay arm, free of charge. The recall began May 23, 2019. Owners may contact KME customer service at 1-800-235-3928.

 

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.safercar.gov.

 

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Title:	Hose Bed Cover Modification
Date:	June 24, 2019
Vehicles:	KME Commercial and Custom Pumpers
Problem:	See Recall 19V267
Corrective Action:	Retrofit Hose Bed Cover with Retention Bracket and Prop Bar
Work Instructions:	See Attachment.
Tools Required:	Common Hand Tools Welder and Supplies Personal Protective Equipment Overhead Crane or Prop Capable of Holding Hose Bed Cover Up Clamp or Vice and tape measure and marker.
KME Parts Required:	Prop Bar Retrofit Kit
KME Contact:	Jim Hauser, Technical Support Manager
Telephone:	570-656-0903
E-Mail:	jhauser@kmefire.com
Mailing Address	KME Fire Apparatus Plant #8 One Industrial Complex Nesquehoning, PA  18240 ATTENTION:  Mr. Jim Hauser

 

WORK INSTRUCTIONS

Figure 1 Before and After Modification

	FIGURE 1 LEGEND
1.  Retention Bracket	3.  Retaining Bracket	5. Shock
2.  Prop Bar	4.  Pivot Bracket

 

NOTE:  It is recommended that two personnel perform these work instructions

• Ensure the park brake is set and the wheels chocked.
• Proper personal protective equipment should be worn.
• If equipped, wear a safety harness before climbing onto the vehicle.
• Use the 3-point rule to climb up to the top of the body.
• Have one person on the ground to hand all tools and parts up to the hosebed.
• Secure an overhead crane to the hose bed lid handle or strap the lid. Slowly lift the hose bed lid approximately 80’s.
• If there is no overhead crane, use a prop that is secured to hold the lid up. A second person should be holding onto the cover to ensure it stays in place.  The second personnel should be located on the officer side of the front hose bed.

NOTE:  THESE INSTRUCTIONS ARE WRITTEN FOR THE LEFT SIDE OF THE HOSE BED.  SOME DESIGNS MAY NOT HAVE ROOM TO ACCOMMODATE THE RETENTION BRACKET.  THE RIGHT SIDE MAY HAVE TO BE USED.

 

Remove/Replace Shocks

1. Ensure the hose bed cover is lifted and secured with a prop or by use of a crane and strap.
2. When the lid is secure, loosen the nut securing the top of the shock on the driver side of the vehicle.
3. Loosen the nut that is securing the bottom of the shock and remove shock.
4. Discard shock and hardware.
5. Install replacement shock. Insert the top of the shock’s threaded stud into the top hole and tighten the nut.

Note:  The top of the shock is the base that does not extend and retract.

6. Insert the bottom of the shock’s threaded stud into the

bottom hole and tighten the nut.

Figure 2 Shock Ball Stud

7. Repeat Steps 2 thru 6 for the opposite side.

Measure for Retention Bracket and Prop Bar, Then Attach

 

Figure 3 Prop Bar and Retaining Bracket Mounted

8. On the driver’s side hosebed wall, attach the prop bar to the center hole on the pivot bracket. Place the pivot bracket (right Side of Figure) approximately 8-inches from the bottom of the shock.  Use a Vice(s) or clamp(s) to hold this in place. (This will free up your hands.)
9. Place the retention bracket about 1-inch from the top of the shock. Swing the prop bar up and into the retention bracket.
10. Assess the preliminary fitting. There is no exact measurement only approximates.  If the prop bar does not meet the retention bracket, prop bar may have to be moved left or right or the retention bracket may have to be moved up or down.  Keep adjusting until the prop bar can be inserted and seated inside the retention bracket.

11. If this placement is correct, mark the area where the retention bracket will be welded.
12. Prep the hose bed cover for welding.
13. Ensure that the welding equipment is properly grounded before attaching the bracket to the hose bed cover.
14. When the bracket is attached and cooled, swing the prop bar up and inside the bracket. If the prop bar does not meet the bracket, the bar may have to be moved closer.  If the lid has to be closed to meet the prop bar, the bar may have to be moved farther away.
15. Once the prop bar is in the correct place, mark where Figure 4 Prop Bar Shown Inside the holes will need to be drilled for the pivot bracket. Carefully, remove the metal shavings around the new Retention Bracket holes and seal the paint before permanently attaching the pivot bracket.  Sealing the holes will protect the paint finish.

16. Fasten the pivot bracket.
17. The prop bar will be attached but still needs the retaining bracket installed to the left side of it.
18. Place the retaining bracket approximately 8-inches to the left of the pivot bracket. If that looks good, mark the holes.  If not, move the bracket left to right until the prop bar is properly balanced and secure.
19. Once the retaining bracket is in the correct place and the holes are marked, drill the holes for the bracket. Carefully, remove the metal shavings around the new holes and seal the paint before permanently attaching the retaining bracket.  Sealing the holes will protect the paint finish.

Figure 5 Prop Bar Bracket Showing

20. Fasten the retaining bracket Position Holes
21. Place the prop bar inside the retention bracket to see the finished project. If no more adjustments required, go to next step.

 

Adjust the Tension on the Shocks

22. Adjust the tension on the shocks.

CAUTION:  The tension can be adjusted on the shocks by releasing the gas in very small increments.

WARNING:  Once the gas is released, it cannot be replenished.  This is why it is very important to release a small amount of gas, then testing the tension.

Both shocks will have to be adjusted.  An allen wrench (hex key) comes with the shock.  The hole is located on the side of the shock that extends and retracts.

Figure 6 Shock Adjustment

Figure 7 Retrofit Complete

Figure 8 Warning Label

24. Install warning label next to the retention bracket inside the hose bed cover. Wipe inside the hose bed cover’s surface clean before applying label.

Figure 10 Label Attached Inside Cover

 

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XXX XX, 2019

 

Name
Address
City, State Zip

 

IMPORTANT SAFETY RECALL NOTICE: 19V267

IMPORTANT SAFETY RECALL

 

This notice applies to your vehicle(s):

 

Dear KME Vehicle Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

 

Why is a recall being conducted?

 KME has decided that a defect which relates to motor vehicle safety exists in certain model year 2012-2019 KME vehicles manufactured from November 2011 through March 2019 equipped with certain sliding, lift-up covers.

KME determined that certain gas springs equipped with an integral, overlapping sleeve lock used to hold a sliding, lift-up cover in the open position can have their sleeve lock inadvertently rotated into a position that may lead to the lock not engaging when necessary.  If the locks do not engage properly, the cover may come down without warning and injure personnel working under the cover.

 

What are we doing about the problem?

KME or its dealers will replace the gas springs on the sliding, lift-up cover at no cost to the owner with either:

1. New gas springs with an integral locking mechanism that cannot be inadvertently disabled, or,
2. New gas springs without the integral locking mechanism and a separate fabricated cover stay arm.

 

What should you do?

If you receive this notification, please contact your KME Dealer or KME Customer Service at (570) 669-5230 to schedule an appointment to have your vehicle(s) remedied.

INCLUDED WITH THIS LETTER IS AN OWNER RESPONSE CARD TO BE FILLED OUT AND RETURNED TO KME.  Please have your Truck VIN or GSO available.  After the repair has been completed, please fill in the appropriate information on the enclosed Owner Response Postcard, sign it, and return it to:

Mail: KME, One Industrial Complex, Nesquehoning, PA 18240
E-mail: bpolgrean@kmefire.com
Fax: (570) 669-5182

 

What if you no longer own this vehicle?

If you are not the current owner of the vehicle, please indicate this on the Owner Response Postcard and return the card to us.

 

Federal law requires any lessor who receives a notification of a safety related defect or noncompliance pertaining to any leased motor vehicle shall send the notice to the lessee within 10 days. If you are no longer the owner of this vehicle, please provide us with any contact information so we may contact the new owner.

If you have already paid to have your vehicle repaired for this condition, you may be eligible for reimbursement of the charges you paid for the repair or replacement of components. To learn more about what you need to do to obtain reimbursement, contact our customer service department.

If after having attempted to take advantage of this recall you believe you have not been able to have your vehicle remedied without charge and within a reasonable amount of time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, D.C., 20590; or call the toll-free Vehicle Safety Hotline at 1888-327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.

 

We apologize for any inconvenience this safety recall may cause, but your safety is our first concern.

 

Sincerely,

KME, Inc

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May 17, 2019

 

SAFETY RECALL NOTICE: 19V267

 

TO: Affected KME Dealers

KME has decided that a defect which relates to motor vehicle safety exists in certain model year 2012-2019 KME vehicles manufactured from November 2011 through March 2019 equipped with certain sliding, lift-up covers.

KME determined that certain gas springs equipped with an integral, overlapping sleeve lock used to hold a sliding, lift-up cover in the open position can have their sleeve lock inadvertently rotated into a position that may lead to the lock not engaging when necessary.  If the locks do not engage properly, the cover may come down without warning and injure personnel working under the cover.

Owners will be notified by mail about the recall and will be instructed to contact their KME Dealer or KME to have new gas springs without the integral locking mechanism and a separate fabricated cover stay arm installed.  The estimated time to complete the replacement is 3.5 hours.  There is no cost to owners for this recall.

Please be reminded that it is a violation of Federal law for you deliver a new motor vehicle or any new or used item of motor vehicle equipment covered by this notification until this defect has been remedied.  Substantial civil penalties apply to violations of this law.

Your assistance with this recall is appreciated. Should you have any questions or concerns, please contact KME Customer Service at (570) 669-5230.

 

Sincerely,

KME, Inc.

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36 Affected Products

9 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-19V267-0523.pdf 134.324KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-19V267-7616.pdf 81.437KB

 

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Recall 573 Report- Amendment 1

RCLRPT-19V267-9618.PDF 217.261KB

 

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Remedy Instructions and TSB

RCRIT-19V267-3814.pdf 615.32KB

 

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Defect Notice 573 Report

RCLRPT-19V267-3767.PDF 217.262KB

 

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Recall Acknowledgement

RCAK-19V267-1404.pdf 246.581KB

 

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Recall Quarterly Report #1, 2019-2

RCLQRT-19V267-0004.PDF 211.126KB

 

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Recall Quarterly Report #2, 2019-3

RCLQRT-19V267-8404.PDF 211.232KB

 

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Recall Quarterly Report #3, 2019-4

RCLQRT-19V267-0174.PDF 211.319KB

 

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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=19V267&docType=RCL

 

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