2021-2022 Coachmen Nova Motorhomes Incorrectly Installed AGM Battery

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September 3, 2021 NHTSA CAMPAIGN NUMBER: 21V692000

Incorrectly Installed AGM Battery

Hydrogen gas inside the vehicle can increase the risk of injury.

 

NHTSA Campaign Number: 21V692

Manufacturer Forest River, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 175

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2021-2022 Coachmen Nova motorhomes. The Absorbed Glass Mat (AGM) battery was incorrectly installed inside the vehicle, which can allow hydrogen gas to enter the vehicle.

 

Remedy

Dealers will install a lithium battery, free of charge. Owners were notified of the defect on September 27, 2021. Owner notification letters were mailed November 1, 2021. Owners may contact Forest River customer service at 1-574-825-6319 or 1-574-825-6625. Forest River’s number for this recall is 225-1416.

 

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.

 


2022 Coachmen Nova
2022 Coachmen Nova

 


Concern:

An AGM Battery was installed on the interior of the vehicle, not inside a battery box or vented to the exterior.

 

Disconnect the vehicles’ battery Positive and Negative, disconnect any House battery(s) Positive and Negative, if equipped with a generator ensure it is off and lastly, ensure the vehicle is disconnected from shore power. Block any tires/wheels to prevent the vehicle from rolling. Failure to do so may result in electrocution, fire or other personal injury, property damage and/or death.

 

INTRODUCTION

This installation guide is intended to aid a certified technician in installing two Battle Born Lithium Batteries in place of the 8D AGM battery installed currently underneath the driver’s side twin bed.

 

The installation will require:

 

Fastener kit:

  • (2) 3/8” x 1 ¼” bolts with (2) nylon lock nuts and (4) washers
  • (20) #8 – 9 x 1 ¼” round washer head screws

 

Tools:

 

STEP 1: REMOVE 8D AGM BATTERY. THE 8D AGM BATTERY IS LOCATED UNDERNEATH THE DRIVER’S SIDE
TWIN BED;

A. REMOVE BED BOARD;

B. REMOVE BATTERY SECUREMENT STRAP BOLTS – 1/2” WRENCH AND SOCKET WRENCH;

C. REMOVE BATTERY AND INVERTER CABLES FROM THE BATTERY POST – 9/16” SOCKET WRENCH;

a. TAPE ENDS OF CABLES TO PREVENT UNINTENTIONAL CONTACT AND ARCING.

D. USE A HAMMER TO KNOCK LOOSE THE 1 ½” SLAT/STICK DIRECTLY ABOVE THE BATTERY. THIS WILL ALLOW THE BATTERY TO BE PULLED OUT OF THE TWIN BED BASE;

 

a. (Optional) remove storage box next to battery to give more space for battery removal. Unscrew at storage box cleats;

b. If the Xantrex XC inverter/charger is mounted on a platform over-top the battery, dismount both the platform and the inverter. Set aside to give space for battery removal.

E. *HEAVY LIFTING* LIFTING PARTNER RECOMMENDED. USE BATTERY HANDLES AND PROPER LIFTING TECHNIQUE TO REMOVE THE 8D AGM BATTERY FROM THE VEHICLE;

F. UNBOLT AND REMOVE THE AGM BATTERY TRAY. LOCK NUTS ARE UNDERNEATH THE VAN. -3/4” WRENCH AND SOCKET WRENCH;

G. SEAL THE TWO 1/2” BOLT HOLES WITH SILICONE.

 

ISOLATION MANAGER

STEP 2: REMOVE BIM160 AND INSTALL Li-BIM225

A. LOCATE THE PRECISION CIRCUITS BIM160 BATTERY ISOLATION MANAGER.

a. IDENTIFY AND LABEL CHASSIS AND COACH BATTERY CABLES. THE BIM160 HAS THE CONTACTOR POSTS LABELED BATT-A AND BATT-B AND THE COACH OR CHASSIS BATTERY CAN BE ON EITHER. THE CHASSIS BATTERY CABLE WILL ROUTE DIRECTLY UNDER THE FLOOR AND WILL NOT BE CONNECTED TO ANY OF THE COACH DEVICES;

B. DISCONNECT CHASSIS BATTERY AND VERIFY THE CABLE AT BIM160 HAS NO POWER;

C. REMOVE THE BATTERY CABLE LUGS FROM THE BATT-A AND BATT-B POSTS USING A ½” SOCKET WRENCH;

D. REMOVE WIRES FROM THE IGN, GND AND SIG POSTS USING A 3/8” SOCKET WRENCH;

E. DISMOUNT THE BIM160 AND MOUNT THE LI-BIM225 SO THAT THE CHASSIS AND COACH BATTERY CABLES CAN REACH THE LI-BIM225 LABELED POSTS;

F. INSTALL BATTERY CABLES ON THE CORRECT LABELED POSTS. INSTALL IGN., GND. AND SIG WIRES TO THEIR RESPECTIVE POSTS.

a. TORQUE THE BATTERY CABLE POSTS TO 50 IN. LBS.

b. TORQUE THE IGN., GND. AND SIG POSTS TO 20 IN. LBS.

G. CONNECT CHASSIS BATTERY;

 

INSTALL BATTLE BORN LITHIUM BATTERIES

STEP 3: LOOK AT AREA AND ENSURE IT IS CLEAR OF ANY OBSTRUCTIONS;

A. SET PLASTIC BATTERY TRAYS IN THE SPACE WHERE THE 8D AGM BATTERY USED TO BE.

a. CIRCUIT BREAKERS DISCONNECT DEVICES, AND/OR BATTERY ISOLATION DEVICES MAY NEED MOVED TO CREATE SPACE FOR NEW BATTERY TRAYS;

B. SET BATTLE BORN LITHIUM BATTERIES IN THE BATTERY TRAYS, SECURE WITH STRAP. ONCE BATTERY FITMENT IS COMPLETE, SECURE THE BATTERY TRAYS TO THE FLOOR WITH #8 X 1 ¼” SCREWS;

C. INSTALL PARALLEL BATTERY JUMPERS ON POSITIVE AND NEGATIVE POSTS WITH 3/8” X 1 ¼” BOLT AND NYLON LOCK NUT (LOOSELY);

a. THE BATTLE BORN BATTERIES COME WITH A 5/16” X 1 ¼” BOLT. USE THE 3/8” HARDWARE FROM THE PARTS KIT INSTEAD;

b. POSITIVE PARALLEL BATTERY JUMPER – FROM POSITIVE POST BATTERY#1 TO POSITIVE POST BATTERY#2. NEGATIVE PARALLEL BATTERY JUMPER – FROM NEGATIVE POST BATTERY#1 TO NEGATIVE POST BATTERY#2;

c. SEE FIGURE 1 FOR PROPER HARDWARE ORDER;

 

FIGURE 1: PROPER ORDER OF HARDWARE TO CONNECT CABLES. WHEN GOING FROM LEFT TO RIGHT IN THE DIAGRAM THE CORRECT ORDER IS: BOLT, WASHER, LUG, TERMINAL, WASHER, AND NUT. IF MULTIPLE LUGS ARE USED, THEY SHOULD BE ON THE SAME SIDE OF THE TERMINAL.

D. INSTALL INVERTER/CHARGER CABLES(2/0 AWG) AND LOAD CABLES(1/0 AWG) ON THE LITHIUM BATTERY PACK SO THAT BOTH POSITIVE(RED) ARE ON THE POSITIVE POST OF BATTERY #1 AND BOTH NEGATIVE(BLACK) ARE ON NEGATIVE POST OF BATTERY #2.

a. SEE FIGURE 2 FOR PROPER CABLE CONFIGURATION.

 

FIGURE 2: TWO 10012/10012H BATTERIES CONNECTED IN PARALLEL TO CREATE A 12V 200Ah BATTERY BANK

 

E. FULLY TIGHTEN 3/8” X 1 ¼” BATTERY POST BOLTS AND LOCK NUTS TO 10 FT. LBS.;

F. REINSTALL STORAGE BOX, INVERTER/CHARGER, AND PLATFORM IF APPLICABLE;

G. REINSTALL 1 1/2” SLAT/STICK WITH SCREWS IN ORIGINAL LOCATION. REINSTALL BED BOARD.

 

ADJUST CHARGE SETTINGS FOR LITHIUM BATTERIES

STEP 4: LITHIUM BATTERIES REQUIRE A DIFFERENT CHARGE PROFILE THAN AGM BATTERIES. XANTREX AND
GOPOWER SETTINGS MUST BE CHANGED BEFORE CHARGING THE BATTLE BORN LITHIUM
BATTERIES;

A. GOPOWER SOLAR CONTROLLER CHARGE SETTING.

a. AT THE GOPOWER SOLAR CONTROLLER, PRESS BATTERY TYPE BUTTON AND HOLD FOR 3 SECONDS TO GO INTO BATTERY TYPE SELECTION MODE. PRESS BATTERY TYPE BUTTON UNTIL THE LIFEPO4 BATTERY TYPE IS ILLUMINATED ON THE BOTTOM OF THE SCREEN. PRESS VOLT/AMP BUTTON TO SELECT AND SAVE THE NEW BATTERY TYPE.

B. XANTREX CHARGER SETTINGS.

a. AT THE XANTREX FREEDOM X CONTROLLER, PRESS AND HOLD THE ‘OK’ BUTTON UNTIL THE SETTING SCREEN IS SHOWN (CENTER SCREEN WILL REPEATEDLY FLASH “[00]”);

b. ADJUST THE SETTINGS USING THE ‘^’ AND ‘OK’ BUTTONS TO MATCH THE TABLE BELOW:

 

Setting# Pro 2000(Gen)
01 OFF
02 11.0
03 300
04 13.1
05 25
06 d15
07 60
08 120
09 2.0
10 300
11 APL
12 90
13 NAt
14 bON
20 LFP
24 *80-100*
26 OFF
28 30

 

c. FOR SETTING #24, THIS SHOULD BE LOCKED(NON-ADJUSTABLE) AT 80. IF IT IS ADJUSTABLE, IT CAN BE SET AT 100A WITH THE BATTLE BORN BATTERIES INSTALLED.

 


This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This notice is also sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Forest River – Office of Corporate Compliance (“OCC”) has decided that a defect, which relates to the motor vehicle safety, exists in certain 2021-2022 Coachmen Nova Class B Motorhome recreational vehicles. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.

 

WHAT IS THE DEFECT/NONCOMPLIANCE?

The AGM Battery was installed on the interior of the vehicle, not inside a battery box vented to the exterior. During charging or overcharging the battery may release hydrogen gas into the vehicle interior.

 

EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.

This condition may result in personal injury or death.

 

WHAT IS FOREST RIVER AND OUR DEALERSHIPS GOING TO DO?

Forest River is notifying dealerships of the recall. You may have the recall corrected at any Forest River dealership. However, it is preferable if you have your selling dealership perform the remedy. Forest River completely covers your cost for the remedy; you will not receive any bill of sale for anything covered under the above recall number.

 

WHAT SHOULD YOU DO?

Please contact your dealer immediately and request a service appointment to schedule the free remedy to install 2 lithium batteries in place of the AGM Battery that is currently installed. The vehicle Owner is responsible for arranging to have the work completed. Please state you have been notified by Forest River of having a recall in process for your vehicle and provide the recall number for the dealership. It is also helpful to the dealership to have a copy of this letter when you take your vehicle in for the recall remedy.

You may also visit www.forestriverinc.com for dealer locations.

 

HOW LONG WILL THE REMEDY PROCESS TAKE?

The estimated time of repair is 2.50 hours. However, the dealership may need to keep your vehicle or schedule an appointment with you for a later date to fit into their regular service schedule.

 

WHAT IF YOU HAVE PREVIOUSLY PAID FOR REPAIRS TO YOUR VEHICLE FOR THIS PARTICULAR CONDITION?

If you have already paid for a repair that is within the scope of this defect under recall, you still need to have this recall inspected and/or performed to ensure the correct parts and procedures were utilized.
Additionally, you may be eligible for a refund of previously paid repairs. Refunds will only be provided for within the scope of this defect under recall.

Please send the service invoice to the following address:

Coachmen Class B Nova
Forest River, Inc.
Attn: WARRANTY MANAGER
423 N Main St
Middlebury, IN 46540

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
COACHMEN NOVA 2021-2022

 


11 Associated Documents

Defect Notice 573 Report

RCLRPT-21V692-3409.PDF 213.87KB

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Recall Acknowledgement

RCAK-21V692-1466.pdf 646.232KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V692-6255.pdf 203.398KB

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Manufacturer Notices(to Dealers,etc)

RCMN-21V692-0408.pdf 215.984KB

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Recall 573 Report – Amendment 2

RCLRPT-21V692-8302.PDF 214.964KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V692-2926.pdf 209.16KB

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Remedy Instructions and TSB

RCRIT-21V692-6737.pdf 361.404KB

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Manufacturer Notices(to Dealers,etc)

RCMN-21V692-9417.pdf 219.489KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V692-9119.PDF 211.13KB

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Recall 573 Report – Amendment 1

RCLRPT-21V692-4007.PDF 214.175KB

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Recall Quarterly Report #2, 2022-1

RCLQRT-21V692-5835.PDF 211.228KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V692&docType=RCL

 


 

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