Incorrect Wiring Missing Over-Current Protection – 2022 Forest River XLR Toy Hauler Recreational Vehicles

“This site contains affiliate links for which OEMDTC may be compensated”

October 22, 2021 NHTSA CAMPAIGN NUMBER: 21V829000

Incorrect Wiring/Missing Over-Current Protection

An electrical short increases the risk of a fire.

 

NHTSA Campaign Number: 21V829

Manufacturer Forest River, Inc.

Components ELECTRICAL SYSTEM, EQUIPMENT

Potential Number of Units Affected 3

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2022 XLR Toy Hauler Recreational Vehicles. The vehicles were incorrectly wired, and they are missing 250AMP over-current protection, which could result in melted wires and an electrical short.

 

Remedy

Dealers will replace the gauge wire, and install a sub panel with the correct breaker, free of charge. Owner notification letters were mailed November 5, 2021. Owners may contact Forest River Customer Service at 1-574-642-0432. Forest River’s number for this recall is 79-1429.

 

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 Forest River XLR Toy Hauler
2022 Forest River XLR Toy Hauler

 


RECALL 21V829 REMEDY INSTRUCTIONS

Make(s): XLR BOOST
Model(s): XLT25LRLE-79
Model Year(s): 2022
Repair Code: RC-003-01-00-004115
Allotted Time: .75 HRS.
Inspection Code: N/A
Allotted Time: N/A
Concern:
An incorrect 12V and 110V gauge wire was installed during manufacturing for the inverter. The 12V is missing a breaker as it the 110V.
Photo(s) Required: YES
Prior Authorization Required: NO
Part(s) Kit Number: 791429
Part(s) Return: N/A

 

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.

 

Parts Kit From XLR:

1 – 250AMP – 12V Breaker
1 – Red – 0/0 Wire with ends crimped/eyelets that is 18” long
1 – Red – 0/0 Wire with ends crimped/eyelets that is 30” long
1 – Black – 0/0 Wire with ends crimped/eyelets that is 48” long
1 – 15AMP – 110V Breaker
1 – 3’ Length of 12/2Ga. 110V Wire
1 – 110V Subpanel
2 – Strain Relief Subpanel Connectors for 110V Wire

 

REMEDY FOR THE 12V SIDE:

STEP 1: LOCATE THE 2 GAUGE 12V BLACK AND RED WIRE(S) THAT ARE ROUTED FROM THE INVERTER TO   THE BATTERY COMPARTMENT;

 

STEP 2: DISCONNECT FROM THE BATTERY AND FROM THE INVERTER, DISCARD OF THE 2 GAUGE BLACK   AND RED WIRES APPROPRIATELY;

 

STEP 3: IN THE PARTS KIT, LOCATE THE 0/0 BLACK WIRE, CONNECT TO THE 12V SIDE OF THE INVERTER AND   ROUTE TO THE NEGATIVE POST OF THE BATTERY (DO NOT HOOK UP);

 

STEP 4: IN THE PARTS KIT, LOCATE THE 0/0 RED WIRE, THERE WILL BE TWO, THE LONGEST RED WIRE WILL   HOOK TO THE INVERTER AND ROUTE CLOSE TO THE BATTERY COMPARTMENT (WITHIN 18”);

 

STEP 5: IN THE PARTS KIT, LOCATE THE 12V – 250AMP BREAKER AND LOCATE A SAFE PLACE WITHIN 18” OF   THE BATTERY TO MOUNT THE 250AMP BREAKER. CONNECT THE 0/0 RED WIRE TO THE 250AMP   BREAKER;

 

STEP 6: IN THE PARTS KIT, LOCATE THE SHORTER 0/0 RED WIRE, CONNECT IT TO THE OTHER POST ON THE  12V – 250AMP BREAKER, THEN ROUTE THE OTHER END OF THE RED WIRE TO THE BATTERY COMPARTMENT (DO NOT HOOK UP);

 

 

REMEDY FOR THE 110V SIDE:

STEP 1: DIRECTLY ABOVE THE INVERTER, INSTALL THE SUBPANEL TO THE WALL (FIG. 1);

 

STEP 2: INSTALL THE 15AMP BREAKER INTO THE SUBPANEL (FIG 1);

 

STEP 3: REMOVE THE CORRESPONDING BREAKER “KNOCK-OUT” FROM THE SUBPANEL’S COVER; Ø NOTE: IT IS EXTREMELY IMPORTANT THAT YOU ONLY TAKE OUT THE “KNOCK-OUT” THAT CORRESPONDS WITH THE BREAKER LOCATION. IN THE EVENT YOU MISTAKENLY REMOVE THE WRONG “KNOCK-OUT” YOU WILL BE REQUIRED TO PROCURE AN APPROVED SUBPANEL “KNOCK-OUT” PLUG AND INSTALL IT IN THE SUBPANEL!

 

STEP 4: LOCATE THE YELLOW 12 GAUGE 110V WIRE THAT IS WIRED INTO THE INVERTERS “OUTPUT SIDE”

AND DISCONNECT THIS WIRE FROM THE INVERTER (FIG. 2);

 

STEP 5: INSTALL A STRAIN RELIEF FROM THE PARTS KIT TO THE YELLOW 12GA. WIRE AND FEED THE WIRE   THROUGH A “KNOCK-OUT” ON THE SIDE OF THE SUBPANEL. ENSURE YOU LEAVE ENOUGH LENGTH OF WIRE TO CONNECT TO THE 15AMP BREAKER, GROUND BAR AND NEUTRAL BAR. THIS WILL NOW   “BE THE FEED SIDE WIRE (FIG. 3);

 

STEP 6: USE THE 3’ 12/2 YELLOW WIRE FROM THE PARTS KIT, INSTALL A STRAIN RELIEF ON ONE END. FEED   THE WIRE THROUGH A SEPARATE “KNOCK-OUT” ON THE SIDE OF THE SUBPANEL. ENSURE YOU LEAVE ENOUGH LENGTH OF WIRE TO CONNECT TO THE “HOT LUG”, GROUND BAR AND NEUTRAL   BAR. THIS WILL BE THE “LOAD SIDE WIRE (FIG. 1);

 

STEP 7: THE LOAD SIDE WIRE NOW NEEDS CONNECTED TO THE INVERTERS “OUTPUT SIDE”. ENSURE TO TRIM EXCESS WIRE AND ONLY STRIP A MINIMAL AMOUNT OF SHEATHING FROM THE BLACK AND   WHITE WIRE, ENOUGH TO PROPERLY ENGAGE WITH THE INVERTER TERMINAL (FIG. 1);

 

STEP 8: ENSURE ALL CONNECTIONS ARE SECURE. PLACE THE SUBPANEL COVER ON;

 

STEP 9: TURN THE 15AMP BREAKER IN THE SUBPANEL TO THE “OFF” POSITION;

 

TEST PROCEDURE:

STEP 1: CONNECT A FULLY CHARGED BATTERY TO THE VEHICLE. CONNECT ALL BATTERY CABLES, INCLUDING THE INVERTER 0/0 HOT AND GROUND;

 

STEP 2: PLUG THE VEHICLE IN TO 110V SHORE POWER;

 

STEP 3: INSPECT ALL CONNECTIONS WHERE WIRING WAS REPLACED. INSPECT INVERTER FOR PROPER   FUNCTIONALITY;

 

STEP 4: INSIDE THE VEHICLE, LOCATE THE RECEPTACLES THAT ARE POWERED BY THE INVERTER. PLUG A FAN OR SOMETHING SIMILAR INTO THESE RECEPTACLES – PLEASE NOTE: THE RECEPTACLES   SHOULD NOT WORK! AS THE 15AMP BREAKER IS “OFF” PER STEP 9 FROM THE 110V REMEDY   PROCEDURES;

 

STEP 5: LOCATE THE SUBPANEL AND TURN THE 15AMP BREAKER TO THE “ON” POSITION. TEST THE   RECEPTACLES AGAIN WITH A FAN OR SOMETHING SIMILAR. THE RECEPTACLES WILL BE IN WORKING   ORDER NOW.

 

STEP 6: CLAIM REPAIR CODE.

 


IMPORTANT SAFETY RECALL

NHTSA RECALL: 21V829
CANADA RECALL: N/A
FR ID: 79-1429

 

November 2021

 

This Notice applies to your vehicle VIN listed above.

 

Dear Forest River Customer:

 

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 2022 XLR Toy Hauler 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 incorrect gauge wire was installed during manufacturing for the inverter as well as the incorrect breaker size.

 

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

The incorrect gauge wire could potently melt, causing a short, which could potentially lead to a fire, property damage and/or personal injury.

 

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. The correct wiring and proper breakers to protect the inverter will be installed. 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 have the correct wiring and proper breakers to protect the inverter 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 .75 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:

XLR
Forest River, Inc.
Attn: WARRANTY MANAGER
2421 Century Dr.
Goshen, IN 46528

 


Chronology :

On October 14, 2021, during a routine Corporate Quality Control inspection the improperly wired inverter was identified.

On October 15, 2021, the manufacturing plant contacted Forest Rivers’ Office of Corporate Compliance and an investigation was started.

On October 18, 2021, the vehicle scope was identified.

On October 22, 2021, Forest River’s Corporate recall committee voted to recall.

On October 28, 2021, The recall was amended to include the remedy.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
FOREST RIVER XLR TOYHAULER 2022

 


10 Associated Documents

Recall Acknowledgement

RCAK-21V829-8037.pdf 645.976KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [630.84 KB]

 


Defect Notice 573 Report

RCLRPT-21V829-3817.PDF 214.372KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [209.35 KB]

 


Recall 573 Report – Amendment 1

RCLRPT-21V829-3781.PDF 215.042KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [210.00 KB]

 


Remedy Instructions and TSB

RCRIT-21V829-0020.pdf 239.469KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [233.86 KB]

 


Manufacturer Notices(to Dealers,etc)

RCMN-21V829-6717.pdf 218.145KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [213.03 KB]

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V829-3934.pdf 208.949KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [204.05 KB]

 


Recall Quarterly Report #1, 2021-4

RCLQRT-21V829-2331.PDF 211.138KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.19 KB]

 


Recall Quarterly Report #2, 2022-1

RCLQRT-21V829-3343.PDF 211.235KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.28 KB]

 


Recall Quarterly Report #3, 2022-2

RCLQRT-21V829-8114.PDF 211.319KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.37 KB]

 


Recall Quarterly Report #4, 2022-3

RCLQRT-21V829-0387.PDF 211.422KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.47 KB]

 


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=21V829&docType=RCL

 


 

“This site contains affiliate links for which OEMDTC may be compensated”
SaleBestseller No. 1
Hamolar 3 Pack 300A Circuit Breaker with Manual Reset Fuse Holder for Car Audio Marine Boat Stereo Switch, with Wire Lugs Copper Washer
  • · Function: This circuit breaker can protect the amplifier from being damaged by the over-load current or voltage. Meanwhile, the power supply can also be protected to avoid battery crack and explosion caused by short circuit.
  • · Specification: Voltage 12-48V DC, compatible with all 12V/24V Systems. Ambient temperature: -32 ° c to 82 ° c (-25 ° f to 180 ° f) ,Accessories added wire lugs and Copper washer.
  • · Manual Reset Circuit Breaker, Use in place of an inline fuse holder, the unique push button reset can also be used as a Kill Switch.
  • · Protects your trolling motor from electrical damage, prevents excessive current and stops power surges from damaging Amps.
  • · Application: Suitable for car audio/video system, boat, trucks, buses, RV's, ATV winches, marine and DC sound amplifier system overload protection.
Bestseller No. 2
Ampper DC 12V - 24V Automatic Reset Circuit Breaker with Cover Stud Bolt for Automotive and More (30A, 2Pcs)
  • Never worry about fuse burn-out with thermal automatic reset feature, power protected when circuit is overloaded / shorting by this overcurrent circuit breaker.
  • #10-32 stud bolt terminals, heavy duty plastic rustproof housing, red cover avoid electrical shorts and corrosion.
  • Application: DC 6-48 V, multi Amps circuit breaker available, can be mounted in 4 orientation.
  • Used for: automotive, electromechanical equipment, vehicle, marine, ATV, RV, off-road, special vehicles, yachts and ships, heavy-duty and truck applications, battery chargers, car engines electrical control etc.
  • Recommend professional installation, 100% SATISFACTION: no reason for return or change.
Bestseller No. 3
4 Pieces DC 12V - 24V Automatic Reset Circuit Breaker Circuit Breaker with Cover Stud Bolt for Automotive and More (30 Amp)
  • Safe and practical to use: never worry about fuse burn-out with thermal automatic reset feature, power protected when circuit is overloaded/ shorting by this over-current circuit breaker
  • Waterproof protective cover: the red protective cover avoid electrical shorts and corrosion, quality and waterproof, 10-32 stud bolt terminals, reliable plastic rustproof housing, can well protect the internal circuit breaker
  • Wide applications: suitable for automotive, electromechanical equipment, vehicle, marine, off road and other vehicles, yachts and ships, truck applications, car engines electrical control etc, bring your life more convenience
  • What you receive: you will receive 4 pieces of DC 12V - 24V automatic reset circuit breakers in this package, enough quantity to meet your various use and replacement, also nice to share with your friends and family who need them
  • Functions: no worry about fuse burn out with thermal automatic reset feature, power protected when circuit is overloaded/ shorting by this over current circuit breaker
Bestseller No. 4
RED WOLF 60 Amp Circuit Breaker W/Ring Terminal 6 Gauge Connector Manual Reset Switch for Boat Trolling Motor Marine ATV Trailer Vehicles Stereo Audio Electronic Battery Solar System Inline Fuse
  • Protect your system: using as circuit breaker and battery Disconnect, allows to charge or maintain the battery without having to disconnect all the wires! protect excessive current between battery or electrical from damage.
  • Solid breaker: new design with waterproof resistant housing and solid build. Fuse breaker Holders have Pass professional electrical performance test and aging test, the switch button is on/off smoothly, reliable quality.
  • Manual reset: Unique on/ off reset push button, mounted on panel or firewall, can used as a kill switch. No need to buy more replacing fuses.
  • Application: used in auxiliary and accessory circuits for fit to Boat Marine RV Yacht Battery Trailer Bus Truck ATV Winches applications. Also used in battery charges and DC sound amplifier system.
  • Max current 60A; Voltage DC 24V. Tubular electrical wire end cable lugs is included.
Bestseller No. 5
Erayco 150 Amp Circuit Breaker with Manual Reset for Car Marine Trolling Motors Boat ATV Manual Power Protect for Audio System Fuse, 12V-48VDC, Waterproof (150A)
  • ✅【Powerful Marine Circuit Protection】 150 amp circuit breaker protects your trolling motor from electrical damage, prevents excessive current and stops power surges from damaging Amps. Ignition Protected, meets safety standards including S.A.E. J1625, J1171, and UL1500, ensuring ignition protection. This marine circuit breaker is designed for safe and reliable operation.
  • ✅【Versatile Applications】 This 12V circuit breaker is suitable for various applications, including marine, automotive, and DC circuits. Perfect for use in auxiliary and accessory circuits for boats, marine vessels, RVs, yachts, batteries, trailers, buses, trucks, ATVs, winches, and more.
  • ✅【Easy Manual Reset and Kill Switch】Unique on/off reset push button allows for easy manual reset, eliminating the need for frequent fuse replacements. Doubles as a convenient kill switch for added functionality.
  • ✅【Solid and Waterproof Design】 Solid build with a new design and waterproof-resistant housing. Fuse breaker holders pass professional electrical performance and aging tests, ensuring a smooth on/off switch operation and reliable quality.
  • ✅【Easy Installation with Rust Prevention】Effortless installation with surface mount capability. Mount on the panel or firewall with the included protective stud insulator. The waterproof cover prevents rust on metal parts, ensuring longevity.
Bestseller No. 6
Gloaso DC 12V Type 1 Low Profile ATC/ATO Fuse Circuit Breaker Auto Reset Circuit Breakers Fuse 12 Volt 5A 10A 15A 20A 25A 30A for Car Boat RV Solar, Mixed 6 Pack
  • 1, 5A/ 10A/ 15A/ 20A/ 25A/ 30A @ 14V dc - 6 Pack ATO/ ATC Automatic Reset (T1) Circuit Breakers
  • 2, NOTE: The height (excluding terminals) of this breaker is 1.16" (29.5 mm), BUT the standard fuse usually is 0.48" (12.19 mm).
  • 3, Materials: UL-Rated 94V0 thermoplastic body. Tin-plated Copper alloy terminals
  • 4, Termination: 5.2mm wide blades compatible with ATO/ ATC type fuse blocks
  • 5, Compliances: SAEJ553; SAEJ1171 ( Ignition protected)
Bestseller No. 7
Allkpoper 30A-300A Premium High-Current Circuit Breakers, Amp Breaker with Fuse Manual Reset Switch Waterproof for Boat Marine RV Yacht Battery Trailer Bus Truck, 12-48V DC (30A)
  • [Application] Ideal For Harsh Environments, suitable for use on auxiliary DC electrical systems. Ideal for use in harsh environments, like motorsport, to provide protection in the event of current overload or short circuit. Switchable surface mount circuit breakers typically found in auxilliary and accessory circuits in trucks, buses, motorhomes & marine systems.
  • [Water resistant housing] Sealed, waterproof unit suitable for use in engine compartments and Bilge area's.
  • [High-current circuit breaker] Using bimetal structures, when the circuit is overloaded, quickly power protection. Widely used in special vehicles, off-road vehicles winch, yachts and ships electrical control.
  • [Connection Stud] Connection Stud Size - M6 x 2 - Nuts supplied with integral lock washers to prevent loosening due to vibration.
  • [Manual power off] We need to disconnect the circuit when refitting, directly press the elliptical red button on the fuse, then the long handle will automatically pop up to cut off the power. Press the long handle back to the original position to form a passage.
Bestseller No. 8
Manual Reset ATC/ATO Multipack 5A, 7.5A, 10A, 15A, 20A, 25A, 30A Circuit Breaker Fuse for Automotive Marine Boat Car Truck RV Audio Battery Protection | Low Profile (Multi Pack)
  • 7 Pack - 5A, 7.5A, 10A, 15A, 20A, 25A, 30A -- ATO / ATC Manual Reset (T3) Circuit Breakers
  • UL-Rated 94V0 thermoplastic body with tin-plated copper alloy terminals
  • 5.2mm wide blades, compatible with ATO/ATC type fuse blocks
  • Automatic recovery functions and overcurrent protection
  • Compliances: SAEJ553; SAEJ1171 (Ignition protected)
Bestseller No. 9
EPLZON 200A Circuit Breaker Resettable Circuit Breaker 200 amp Self Recovery Circuit Breaker Manual Reset Button for Car Audio and Amps Protection
  • Features: Large current thermal trip circuit breaker with manual reset switch, suitable for auxiliary DC electrical system, when the current reaches a predetermined value, the fuse can be restored to automatically disconnect and protect the circuit
  • Circuit protection function: When the current reaches a predetermined value, the recoverable fuse will automatically disconnect to protect the circuit. Prevent excessive current and protect electrical appliances. Overcurrent protection, overvoltage protection, residual current protection, overcharge protection.
  • Simple installation: No need to replace the built-in fuse, and it can also be used as an on/off button battery switch. The circuit breaker has simple installation steps and can be installed on any flat panel, or on the wall or in the car.
  • Material and wiring: The shell and parts are made of highly flame-retardant and anti-vibration plastics, with a long service life. It accepts 0/2/4/8 specification power cords with adapters for direct connection with all 12, 24 volt systems
  • Application: Provide protection for overload or short-circuit current when using high current electricity such as automobiles, ships, ships, RVs, caravans, tractors, loudspeakers, horns, automobile dual-battery isolators, and winches. Audio circuit breakers, Large current thermal trip circuit breaker with manual reset switch, suitable for auxiliary DC electrical system.
Bestseller No. 10
Fuse Holders Inverter Circuit Breaker Car Audio Solar Energy Inline Circuit Breaker Fuse Inverter with Waterproof Cover for Motor Auto Car Marine Boat (300A)
  • Suitable for car audio/video system, Boat, trucks, buses, RV's, ATV Winches and marine and DC sound amplifier system overload protection
  • Built-in High Current Terminal Blocks,Stops Power Surges From Damaging Your Amps,Save Your Money to Replacing Fuses
  • New design Manual Reset Circuit Breaker 80A-300A for choose and Compatible with all 12, 24 Volt Systems
  • Unique Push Button Reset and Save Your Money to Replacing Fuses, 0-4awg Wire gauge
  • One year warranty. Your satisfaction is our priority, any questions about our item, feel free to contact us

Last update on 2024-03-13 / Affiliate links / Images from Amazon Product Advertising API

This product presentation was made with AAWP plugin.

 


Leave a Comment

Share to...