Corrosion on Battery Studs – 2016-2020 KME Predator Custom, Predator Panther, Predator Severe Service, & 2016-2019 Commercial Cab/Chassis Vehicles

April 2, 2020 NHTSA CAMPAIGN NUMBER: 20V192000

Corrosion on Battery Studs

An electrical short circuit may drain the battery, preventing the emergency vehicle from being able to operate, thereby increasing the risk of injury in the event of an emergency.

 

NHTSA Campaign Number: 20V192

Manufacturer Kovatch Mobile Equipment Corp.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 678

 

Summary

Kovatch Mobile Equipment Corp. (KME) is recalling certain 2016-2020 Predator Custom, Predator Panther, Predator Severe Service, and 2016-2019 Commercial Cab/Chassis vehicles. An electrical short circuit can occur due to a build-up of corrosion between the positive battery jumper stud and the retaining ring for the stud.

 

Remedy

KME will notify owners, and dealers will clean the jumper studs, connection surfaces, and connections. Additionally, the connection surfaces and wire terminals will then be sealed with a silicone electrical sealant. All services will be performed free of charge. The recall began May 18, 2020. 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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ONRD – 00005052020- 26

TECHNICAL SERVICE BULLETIN

Title:	Jumper Stud Inspection
Date:	May 5, 2020
Vehicles:	KME Custom Chassis’ that have remote jumper studs mounted using metallic mounting plates/angles.
Issue:	Some customers are reporting excessive corrosion on the battery jumper studs.
Corrective Action:	Inspect jumper studs for corrosion or physical damage, clean studs, terminals and  surrounding area.  Coat the stud and surrounding area with 738, electrical sealant.
Work Instructions:	See Attachment.
Tools Required:	Common Hand Tools Dow-Corning 738 white electrical sealant Personal Protective Equipment (Protective Glasses, Gloves, Face Shield, etc.) Voltage Meter Creeper Wire Brush
KME Parts Required:	Not Applicable
KME CONTACT:	Jim Hauser, Technical Support Manager
TELEPHONE:	570-656-0903
EMAIL:	jhauser@kmefire.com
MAILING ADDRESS:	KME Fire Apparatus Plant #8 One Industrial Complex Nesquehoning, PA  18240ATTENTION:  Mr. Jim Hauser

 

WORK INSTRUCTIONS 

NOTE:  If the jumper stud connections have already been coated with any other corrosion preventative, that coating must be removed, and the surfaces cleaned prior to applying the electrical sealant described in this bulletin.

 

NOTE:  Technician is responsible for following this procedure to verify that the battery jumper studs have been inspected and properly sealed.

 

1. Ensure appropriate PPE is provided and worn before performing steps in this bulletin.

 

2. Ensure the wheels are chocked and the vehicle is parked in a safe location.

 

3. Ensure that the Master Switch is OFF inside the Cab.

 

4. Disconnect both positive and negative jumper stud cables from the battery post.

 

5. Verify with a voltmeter there is no voltage across the jumper studs.

 

6. Remove the mounting bracket from the battery box to gain access to the back of the studs.

 

7. Inspect studs for corrosion or physical damage.

 

8. Remove terminals from both the positive and negative studs.

 

9. Clean the contact surface of the stud and the surrounding area. (Use a wire brush.)

 

10. Clean the contact surfaces of the positive and negative cable terminals. (Use a wire brush.)

 

11. Reconnect positive and negative cable terminals to the studs.

 

12. Coat the stud and surrounding area with 738, electrical sealant.

 

NOTE:  The sealant must go inside the gap between the metal stud and the metal cable mounting ring on cable terminals, top and bottom.  See photos on next page of this bulletin.

 

13. Reinstall the mounting bracket to the battery box.

 

14. Reconnect the jumper stud positive cable to the positive battery post.

 

15. Reconnect the jumper stud negative cable to the negative battery post.

 

16. Verify with a voltmeter that there is battery power across the jumper.

 

17. When the work is finished, contact KME. See KME Contact on first page of the bulletin.

 

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May 13, 2020

Name
Address
City, State Zip

 

IMPORTANT SAFETY RECALL NOTICE: 20V192

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 2016-2020 KME vehicles manufactured from January 2016 through February 2020.

Vehicles included in this recall have battery jumper studs mounted to a bracket that is attached to the battery mounting tray and the jumper stud connection was sprayed with an oil-based battery corrosion preventative.  The wire terminals for the jumper studs have a small gap between the jumper stud connection and the ground.  If the corrosion preventative is lacking by either its removal or insufficient application and corrosion is allowed to accumulate, a short circuit may occur between the stud and the retaining ring.  An electric arc may occur near the battery box, potentially draining the battery, preventing the vehicle from performing its mission.

 

What are we doing about the problem?

KME or its Dealers will clean the jumper studs, connection surfaces, and connections.  The connection surfaces and wire terminals will then be sealed with a silicone electrical sealant.  Estimated time for the remedy is 1 hour.

 

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 at (570) 669-5230.

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 13, 2020

SAFETY RECALL NOTICE: 20V192

 

TO: Affected KME Dealers

KME has decided that a defect which relates to motor vehicle safety exists in certain model year 2016-2020 KME vehicles manufactured from January 2016 through February 2020.

 

Vehicles included in this recall have battery jumper studs mounted to a bracket that is attached to the battery mounting tray and the jumper stud connection was sprayed with an oil-based battery corrosion preventative.  The wire terminals for the jumper studs have a small gap between the jumper stud connection and the ground.  If the corrosion preventative is lacking by either its removal or insufficient application and corrosion is allowed to accumulate, a short circuit may occur between the stud and the retaining ring.

 

KME or its Dealers will clean the jumper studs, connection surfaces, and connections.  The connection surfaces and wire terminals will then be sealed with a silicone electrical sealant.  Estimated time for the remedy is 1 hour.

 

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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14 Affected Products

Vehicles

MAKE	MODEL	YEAR
KME	COMMERCIALCAB/ CHASSIS	2016-2019
KME	PREDATOR	2016-2020
KME	PREDATOR PANTHER	2016-2020

 

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8 Associated Documents

Remedy Instructions and TSB

RCRIT-20V192-8444.pdf 417.14KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V192-5723.pdf 81.553KB

 

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V192-4686.PDF 211.12KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V192-3071.pdf 134.424KB

 

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Recall Acknowledgement

RCAK-20V192-3417.pdf 244.926KB

 

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Defect Notice 573 Report

RCLRPT-20V192-8673.PDF 216.53KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V192-0305.PDF 211.223KB

 

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V192-7241.PDF 211.31KB

 

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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=20V192&docType=RCL

 

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