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February 10, 2021 NHTSA CAMPAIGN NUMBER: 21V063000
Improperly Installed Power Cables
The power cables may chafe, increasing the risk of a fire.
NHTSA Campaign Number: 21V063
Manufacturer Motor Coach Industries
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 1,229
Summary
Motor Coach Industries (MCI) is recalling certain 2018-2021 J4500 and 2018-2020 D45CRTLE vehicles. The power cables may have been improperly installed and routed in the vehicle battery compartment, which may result in chafing.
Remedy
MCI will notify owners, and dealers will inspect and if necessary, correct the clearance for the power cables in the battery compartment, free of charge. The recall began March 12, 2021. Owners may contact MCI customer service at 1-800-241-2947. MCI’s number for this recall is R21-003.
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.
| Subject: Battery Compartment Cable Routing Inspection & Correction | |||
| Field Change Program:
Field Campaign |
FCP Number:
491 |
Revision:
A |
Date:
02/22/2021 |
| Coach Section:
07-Electrical |
P/N:
N/A |
Type:
Safety Recall |
|
| Ref. NHTSA Recall No.: 21V-063 | Ref. Transport Canada Recall No.:
2021-058 |
Application:
| Coach Model | Model Year | VIN |
| J4500 | 2018 – 2021 | 68400, 68468 – 68513, 68515 – 68535, 68537 – 68559, 68562 – 68605, 68607 – 68614, 68616, 68617, 68619 – 68657, 68659 – 68677, 68679 – 68690, 68692 – 68697, 68699 – 68716, 68718, 68720, 68722 – 68740, 68742 – 68745, 68747 – 68771, 68773 – 68802, 68804 – 68871, 68873 – 68876, 68878 – 68891, 68895, 68898 – 68906, 68908, 68910 – 68930, 68933, 68936 – 68964, 68966 – 68998, 69001 – 69029, 69031 – 69101, 69103 – 69145, 69148 – 69195, 69197 – 69222, 69224 – 69236, 69238 – 69260, 69262 – 69293, 69295 – 69300, 69302 – 69340, 69342, 69344 – 69348, 69350 – 69394, 69396 – 69407, 69409 – 69430, 69432 – 69445, 69449, 69456 – 69458, 69461 – 69490, 69493 – 69496, 69498 – 69504, 69507, 69515 – 69566, 69569 – 69574, 69577, 69578, 69581 – 69584, 69587 – 69590, 69592 – 69625, 69627 – 69631, 69633 – 69642, 69644 – 69672, 69679 – 69696, 69699 – 69705, 69707, 69708, 69710 – 69721, 69723 – 69754, 69759 – 69765, 69768 – 69770, 69773, 69774, 69782, 69785 – 69794, 69803 – 69811, 69814 – 69819, 69821 – 69825, 69827, 69834 – 69839, 69863, 69875 – 69880, 69885, 69895, 69896, 69926, 69927, 69930 – 69935, 69937, 69938, 69945 – 69948 |
| 45DCRLE | 2018 – 2020 | 68691, 68717, 81000 – 81087, 81088, 81089 |
| This field campaign does not necessarily apply to all the above-mentioned coaches. The owners of the coaches affected by this field campaign will be advised by a letter indicating the Vehicle Identification Number (VIN) of each applicable coach. | ||
WARNING
Read this entire procedure before beginning work.
Use Safe Shop Practices at All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and protective gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Position the ENGINE RUN and ENGINE START switches on the engine compartment remote control box to the OFF
e. Allow enough time for components to cool down prior to working in the engine compartment.
1.0 Description
This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
Power cables with inadequate clearance from other items of equipment, may chafe which increases the potential for vehicle fire.
Customer complaint:
Motor Coach Industries (MCI) has become aware that, on certain J4500 and 45DCRLE coaches power cables in battery compartment may potentially come in contact with a few metal edges and chafe.
Cause:
Cables are improperly secured in battery compartment.
Corrective action:
MCI recommends owners of the affected coaches have the following procedure performed to inspect cable routing in battery compartment and rework if required.
2.0 Material requirements
| ITEM | PART NO | QTY | U/M | DESCRIPTION |
| 1 | 21-7201-8 | 1 | FT | Trimlock-Aluminum |
| 2 | 6486917 | 1 | EA | Nut- Acorn 1/4-20 5/16” Nylon |
| 3 | 19-11-259 | 2 | EA | Tyrap-13.38” Long |
Refer to Sections 5.1.1, 5.2.1, and 5.3.1 for additional material
3.0 Special tools
No special tools required.
4.0 Inspection
Open battery compartment door and verify if any of the power cables are in contact with or are rubbing against the parcel rack A/C line copper fittings.
If cables are found to be touching or rubbing on the copper lines, refer to Section 5.1 for routing correction.
| Good
Gap between cables and fitting. Continue with next steps of inspection |
Bad
Cable touching copper fitting. Refer to Section 5.1 for routing correction |
In baggage bay #3 compartment, remove and save five bolts and two screws securing the battery compartment access panel. Save the panel. If cables are found to be touching or rubbing on the copper lines, refer to Section 5.1 for routing correction.
Inspect to see if cables are unsecured and close to the ground stud on the coach frame.
If the cables are unsecured, refer to Section 5.2 for routing correction.
| Good
Gap between cables and ground stud. Continue with next steps of inspection |
Bad
Cable close to ground stud. Refer to Section 5.2 for routing correction |
Inspect to see if the adhesive tie bases securing the 110V harness in baggage bay #3 compartment are still intact.
If the adhesive tie base are failed, refer to Section 5.3 for routing correction. Otherwise, inspection is completed.
| Good
Adhesive base intact. Inspection completed. |
Bad
Adhesive base failed. Refer to section 5.3 for rework |
5.0 Cable routing correction
5.1 Battery compartment
5.1.1 Material requirements
| ITEM | PART NO | QTY | U/M | DESCRIPTION |
| 1 | 19-11-259 | 10 | EA | Tyrap-13.38” Long |
5.1.2 Adjusting cable routing in battery compartment
Cut the cable ties as needed behind the battery box and between baggage bay panel and HVAC duct to release tension in the center tunnel harness branch going over the evaporator coolant lines. Pull the center tunnel harness nearly 2” up.
Cut the cable ties as needed
Release the tension in center tunnel harness branch and pull it up by 2”
Loosen the ground cable stud and pull the ground cables outboard.
Pull ground cables outboard
Loosen the ground stud
Tighten the cable tie securing the cables and move the cables as high as possible.
Tighten the cable tie by pushing the cables high
Re-secure the cables using a cable tie, MCI P/N: 19-11-259, ensuring the ground cables are outboard. Torque the ground stud to 19 Ft-Lbs.
Re-secure the cables using cable tie
Pull the cables together and secure them with a cable tie, MCI P/N: 19-11-259, so that they move away from the fitting in the battery compartment.
Secure the cables with a cable tie
Secure the cables in battery compartment as required using cable ties, MCI P/N: 19-11259.
Secure the cables using cable ties, 19-11-259
5.2 Ground stud
5.2.1 Material requirements
| ITEM | PART NO | QTY | U/M | DESCRIPTION |
| 1 | 19-11-259 | 1 | EA | Tyrap-13.38” Long |
5.2.2 Adjusting cable routing by ground stud
Pull all the cables coming out of battery compartment away from ground stud and secure them with a zip tie, MCI P/N: 19-11-259.
Secure the cables with a cable tie
5.3 110V harness
5.3.1 Material requirements
| ITEM | PART NO | QTY | U/M | DESCRIPTION |
| 1 | 19-04-0283 | 2 | EA | Tie base- Adhesive mount |
| 2 | 19-11-259 | 2 | EA | Tyrap-13.38” Long |
5.3.2 Re-installing adhesive tie bases
Cut the cable ties securing the 110V harness. Discard the tie base.
Cut and discard cable tie and tie base
Clean the frame with isopropyl alcohol and install new adhesive tie bases, MCI P/N: 1904-0283 and secure the cable with cable ties, MCI P/N: 19-11-259
Clean the frame with isopropyl alcohol and secure 110V harness using tie bases, 19-04-0283, and cable ties, 19-11-259
6.0 Coach assembly
6.1 Installing acorn nut
Install acorn plastic nut, MCI P/N: 6486917, to the ground stud.
Install acorn nut, 6486917, to the ground stud
Acorn nut, 6486917
6.2 Securing cables above evaporator compartment
Secure the cables using cable ties, MCI P/N: 19-11-259, above evaporator compartment to move them away from rivnuts in harness cover panel.
Secure cables using cable ties, 19-11-259, and lift them from rivnuts
6.3 Installing trimlock
Re-install the battery compartment access panel using existing hardware.
Re-install the panel using existing hardware
Install trimlock, MCI P/N: 21-7201-8, to the access panel front edge as shown below.
Install trimlock, 21-7201-8
7.0 Field Change Program Conditions:
The parts required for this change will be supplied without charge.
A labor allowance of 15 minutes will be granted for the inspection.
A labor allowance of 15 minutes will be granted for the rework.
This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt of the attached “MCI Field Change Program Verification Form” and a “Warranty Claim Form” as detailed in your Owner Warranty manual to MCI’s Warranty department. A “MCI Field Change Program Verification Form” needs to be submitted for each VIN affected. Photocopy the attached “MCI Field Change Program Verification Form” as required for the number of affected coaches in your fleet.
Motor Coach apologizes for any inconvenience resulting from this campaign but urges you to implement this change as soon as possible.
Sincerely,
7.1 MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION
IMPORTANT SAFETY RECALL NOTICE
11 March 2021
Subject: Motor Vehicle Safety Recall 21V-063 – Power Cable Routing
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Motor Coach Industries Inc. (“MCI”) has decided that a defect whichrelatesto motor vehicle safety exists on certain MCI coaches. MCI records indicate that you are the owner or operator of the following vehicle(s)includedin this recall:
MAKE: MCI
BUS MODEL: J4500
VIN(s)
2MG3JM
2MG3JM
2MG3JM
2MG3JM
2MG3JM
2MG3JM
2MG3JM
2MG3JMB
2MG3JMB
2MG3JMB
2MG3JMB
2MG3JMB
2MG3JMN
2MG3JMNA
On vehicles manufacturedbetween October 2017 and December 2020, the power cables in the vehicle battery compartment may not have been installed and routed in accordance with the MCI assembly instructions. There are potential concerns that the power cables within that compartment may not have the optimum routing configuration, causing these cables to be too close to other equipment, creating the potential to chafe.
This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
Power cables with inadequate clearance from other items of equipment, may chafe which increases the potential for vehicle fire.
MCI will remedy the affected coaches at no cost to customers. You may contact the MCI Customer Service Line at 1-800-241-2947 if you have any questions about this recall campaign or wish to arrange to have your vehicle(s) repaired at an authorized MCI service center.
MCI estimates that it will take approximately 0.25 hours per vehicle to inspect and an additional 0.25 hours to make any necessary repairs. Please see the enclosed MCI Service Bulletin FCP 491 for further information.
Submittal of MCI Warranty Claim Forms may be completed on MCI’s website at https://fleetsupportiw.mcicoach.com/iwarranty/signon (click on Customer Care System), or a photocopy of the Warranty Claim Form found in the Warranty Manual can be mailed / faxed to the MCI Warranty Department. Please refer to Service Bulletin FCP 491, and your OWNER LIMITED WARRANTY MANUAL, for more detailed information.
After contacting MCI Customer Service, if you are unsatisfied with the way in which this recall was conducted, you may submit a written complaint to:
Administrator,
National Highway Traffic Safety Administration,
1200 New Jersey Ave. SE,
Washington, DC, 20590,
or call 1-888-327-4236 (TTY: 1-800-424-9153);
or go to https://www.safercar.gov.
If you are a lessor of vehicles which are identified above, it is required that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If you no longer own this vehicle, or it has been removed from operation permanently, please contact the MCI Customer Service Line at 1-800-241-2947 with all of the information you have regarding the current owner/operator of the vehicle(s).
If you had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact the MCI Customer Service Line at 1-800-241-2947 for further information in that regard.
We regret any inconvenience which this action may cause you. However, we are concerned about the safety of your passengers and employees.
Thank you for your attention to this important matter. Sincerely,
By: Kerry Legg
Vehicle Safety & Regulatory Compliance Manager
(204) 224-6706
cc: Scott Halbesma – Vice President, Customer Care
Enclosure: MCI Service Bulletin FCP 491
7 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| MCI | D45 CRT LE | 2018-2020 |
| MCI | J4500 | 2018-2021 |
7 Associated Documents
Remedy Instructions and TSB
RCRIT-21V063-3868.pdf 4128.55KB
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Owner Notification Letter(Part 577)
RCONL-21V063-1430.pdf 757.01KB
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Recall Quarterly Report #1, 2021-1
RCLQRT-21V063-9261.PDF 211.133KB
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Recall Acknowledgement
RCAK-21V063-9698.pdf 645.196KB
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Defect Notice 573 Report
RCLRPT-21V063-8106.PDF 217.425KB
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Recall Quarterly Report #3, 2021-3
RCLQRT-21V063-4758.PDF 211.317KB
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Recall Quarterly Report #4, 2021-4
RCLQRT-21V063-6675.PDF 211.426KB
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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=21V063&docType=RCL
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