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December 14, 2021 NHTSA CAMPAIGN NUMBER: 21V968000
Circuit May Fail Causing Loss of Braking Assist
A loss of braking and steering assist increases the risk of a crash.
NHTSA Campaign Number: 21V968
Manufacturer Lion Electric Company
Components ELECTRICAL SYSTEM, SERVICE BRAKES, HYDRAULIC, STEERING
Potential Number of Units Affected 170
Summary
Lion Electric Company is recalling certain 2017-2021 LionC school buses. A 12V circuit breaker switch may fail, causing a loss of braking and steering assist.
Remedy
Lion Electric Company will inspect and repair the 12V circuit breaker switch, free of charge. Owner notification letters were mailed January 10, 2021. Owners may contact Lion Electric Company customer service at 1-855-546-6706.
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.
Preventive Measures for 12V Power System (LionC units in service)
This document is to inform you of the preventive measures that operators must perform on LionC in service to prevent the risk of low voltage (12volt) loss, until the corrective action (recall) is taken.
IMPORTANT: The switch should never be used while the vehicle is running on either 12V or HV (unless it is an emergency). The switch should only be used for LionC maintenance tasks.
Chronology :
September 2, 2021: LionC accident on King Street in Sherbrooke.
September 30: Vehicle inspection by all parties involved at 241 Léger Street in Sherbrooke.
October 6: EPN 835 (Engineering Project Numbers) openening.
October 8: Beginning of the procedure of the preliminary tests.
November 7: Attempts to reproduce the cause of the accident at the vehicular level.
November 26: Identification of the present fix in the test series and validation.
To date, the investigation is still ongoing to identify the cause of the accident.
12 Associated Documents
Recall 573 Report – December 2, 2021
RCLRPT-21V968-9815.PDF 213.609KB
Recall 573 Report – December 22, 2021
RCLRPT-21V968-2660.PDF 213.604KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V968-7644.pdf 145.659KB
Defect Notice 573 Report
RCLRPT-21V968-8549.PDF 213.613KB
Recall 573 Report-Amendment 1
RCLRPT-21V968-4062.PDF 213.604KB
Recall Acknowledgement
RCAK-21V968-3223.pdf 645.588KB
Safety Bulletin
RCSB-21V968-9784.pdf 787.071KB
Recall 573 Report
RCLRPT-21V968-6204.PDF 213.645KB
Remedy Instructions and TSB
RCRIT-21V968-9079.pdf 2385.227KB
Recall 573 Report- Amendment 4 (03/01/2022)
RCLRPT-21V968-6294.PDF 213.742KB
Recall Quarterly Report #1, 2022-1
RCLQRT-21V968-7539.PDF 211.134KB
Recall Quarterly Report #2, 2022-2
RCLQRT-21V968-5769.PDF 211.233KB
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=21V968&docType=RCL
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SEOCONTENT-START
Page 1 December 16th, 2021 Preventive Measures for 12V Power System (LionC units in service) This document is to inform you of the preventive measures that operators must perform on LionC in service to prevent the risk of low voltage (12volt) loss, until the corrective action (recall) is taken. IMPORTANT: The switch should never be used while the vehicle is running on either 12V or HV (unless it is an emergency). The switch should only be used for LionC maintenance tasks. Description of the vehicle (s) concerned by these recommendations Type Lion Model (s) Lion C Model (s) year 2017 to 2022 List of tools required • Torque wrench (with valid calibration) capable of 80 to 200 in-lbs (9 to 22 Nm) • Socket 9/16 • Socket wrench • Clamps • Flashlight Items to inspect on vehicles 1. Check the torque of the circuit breaker bolts: a. Locate the 12V battery access panel; b. Turn the main switch to the “OFF” position; c. Unscrew the battery holder with the butterfly bolts (See the blue circles in Figure 1.) Page 2 Figure 1 – Battery Holder d. Remove the caps from the electrical connections of the battery. With a 9/16 socket or wrench, unscrew the electrical connections (note: negative first followed by positive) for both batteries (4 bolts), circled in green in Figure 2 and Figure 3 Figure 2 – Electric connections (front battery) Page 3 Figure 3 – Electric connections (rear battery) e. Remove the two batteries from the battery compartment. IMPORTANT: It is STRONGLY recommended that the 12V lead-acid batteries not be tilted, ensure that batteries are handled horizontally. Page 4 2. Exterior switch inspection: a. Check the switch for any abnormalities: i) No discoloration of bolts; ii) No sign of melting of the plastic of the switch; iii) The bolts must be properly seated and flat on the face exposed to the rear of the switch (ref.: Figure 5 and Figure 6) iv) The lock washer must be well fixed between the lug and the bolt (ref.: Figure 7); v) Slightly push on the cables from front to back (ref.: Figure 7) No play can be tolerated in this direction, if any play is apparent, replace the switch. The Figure 4 shows a new switch. Note that the bolts are well inserted into the plastic, the color of the bolts and nuts is not discolored, and there is no sign of plastic melting: Figure 4 – Switch in good condition Page 5 Figure 5 and Figure 6 show a switch in bad condition: Figure 5: Switch in bad condition Figure 6: Switch in bad condition Incorrect: bolt not flat on the back surface and discolored. Correct: bolt that is flat to the rear plastic surface and not discolored. Correct: bolt that is flat to the rear plastic surface and not discolored. Incorrect: bolt not flat on the back surface and discolored. Page 6 Figure 7 – Perpendicular verification of electrical connections IMPORTANT: If you notice severe deficiencies in any of the above inspection areas, it is strongly recommended that the LionC vehicle not be operated until the defective parts are replaced. Correct: lock washer well fixed between the lug and the bolt Page 7 3. Tightening the switch nuts: a. Locate the switch bolts (ref.: Figure 8 and Figure 9); Figure 8 – Switch in good condition Figure 9 – Switch Bolt Location b. Using the torque wrench and a 9/16 socket, set the torque wrench to 80 in-lbs (9 Nm); c. Torque both nuts to 80 in-lbs. (9 Nm). Location of bolts on the switch (ref. Figure 5) Page 8 4. Re-installing the batteries: a. Put back in place the two batteries in the compartment by reversing steps 1.c to 1.e.; For step 1.d (tightening the battery nuts), the tightening torque for the battery terminals is 195 in-lbs (22 Nm) and remember to put the positive back on first followed by the negative. Refer to Figure 2 and Figure 3; b. Ensure that the wire connection lugs on the 4 battery posts are also tightened to 195 in-lbs (22 Nm), see Figure 10. c. During installation, note the position of the battery clips as shown in Figure 11, and hand tighten the wing nuts until they are tight, try to move the batteries and re-tighten if necessary. c. Validate the installation according to section 5 below. Figure 10: Battery cable lugs (195 in-lbs) Page 9 Figure 11 – Battery holders Page 10 5. Validation a. Turn the outside switch to the “ON” position; b. With no key in the ignition, press on the brake pedal, make sure the emergency brake pump activates (hydraulic pump noise); c. Stop pressing the brake pedal, make sure the emergency brake pump stops; d. Turn the ignition key to the “ON” position. Make sure the vehicle is turned on and that no error messages appear on the screen; e. Turn the ignition key to the “START” position and make sure that the high voltage is activated and that no error message appears on the screen; f. Turn off the ignition. IMPORTANT: If you notice severe deficiencies in any of the above inspection areas, it is strongly recommended that the LionC vehicle not be operated until the defective parts are replaced If you are uncertain, please contact the service department at this toll-free number: 1-855-546-6706 ext. :229. Engineering Manager (Service) Engineering Manager (Program)
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Pour information, contactez / For information, contact https://thelionelectric.com/fr/pieces OR 1-855-546-6706 Page 1 of 23 BS-223 Instruction des correctifs à apporter au système de 12V / BS-223 Instruction for 12V System Corrections Cliquez pour choisir Rappel ou Bulletin de Service : BS-0223 Numéro Transport Canada / Transport Canada Number : 20121-742 Numéro NHTSA / NHTSA Number: N/A Date : 2021-11-22 Modèle / Model : LIONC Année de Fabrication / Year of Manufacture : 2014-2021 EPN : 0835 Table des matières / Table of Content 1. PRÉREQUIS / PREREQUISITES ………………………………………………………………………………………………………………… 4 2. DÉMONTAGE DU COUPE-CIRCUIT / REMOVAL OF THE KILL SWITCH ……………………… Erreur ! Signet non défini. 3. INSTALLATION DU SUPPORT CÂBLE / CÂBLE BRACKET INSTALLATION ………………………………………………………. 23 4. INSTALLATION DU SUPPORT PORTE-FUSIBLE ET PORTE-RELAIS/FUSE HOLDER BRACKET INSTALLATION…………. 5. CONNECTION DU HARNAIS LV DANS LE BOITIER A BATTERIES 12V /LV HARNESS CONNECTION UNDER THE 12V BATTERIES BOX……………………………………………………………………………………………………………………………………………………… 6. CONNECTION DU HARNAIS LV DANS LE PDC / LV HARNESS CONNECTION IN THE PDC……………………………………… 7.RECONNECTION DES CABLES ET DU PORTE-FUSIBLE DANS LE BOITIER A BATTERIES 12V /RECONNECTING THE CABLES AND FUSE HOLDER IN THE 12V BATTRERIES BOX…………………………………………………………………………………… 8. TEST/TEST HISTORIQUE DES RÉVISIONS / REVISIONS HISTORY ……………………………………………………………………………………. 39 : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 2 of 23 Problématique du Rappel ou Bulletin de service Recall-Service Bulletin Problem Une défaillance de l’interrupteur du coupe-circuit 12V pourrait causer la perte de l’assistance de direction et une perte de la capacité de freinage (systèmes primaire et secondaire). A failure of the 12V circuit breaker kill switch could result in the loss of steering assist and a loss of braking capability (primary and secondary systems). Remède du Rappel ou Bulletin de service Recall-Service Bulletin Remedy Lion a identifié une série de corrections à apporter au circuit 12V afin d’améliorer la sécurité du véhicule. Lion has found a series of corrections to apply to the 12V circuit to improve the vehicle safety. Unité Lion PN / Lion PN Unit Ensemble d’écrous et boulons BS-0203 BS-0203 nuts and bolts kit Quantité / Quantity BS-223_00 Kit de rétrofit coupe-circuit Kill switch retrofit kit 1 Lion PN / Lion PN Description / Description Description Quantité / Quantity 14802621_00 Boulon M6 80mm Full thread Bolt M6 80mm Full thread 1 14802612_00 Boulon M6 70mm Full thread Bolt M6 70mm Full thread 1 14811062_00 Collier en P 0,75 P Clamp 0,75 1 14800662_00 Collier en P 0,875 P Clamp 0,875 2 14801308_01 Espaceur 45mm Spacer 45mm 2 14802388_00 Rivet-écrou M6 Rivet Nut M6 2 14802186_00 Rondelle oversized, M6, ZN Washer oversized, M6, ZN 2 12801272_01 Harnais Électrique Electrical harness 1 12610353_00 Raccord rouge Red splice 2 12610352_00 Raccord bleu Blue Splice 1 12600703_00 Cavity plugs Cavity plugs 4 12801306_01 Câble électrique Electrical cable 1 12810599_01 Câble électrique Electrical cable 1 14810832_00 Écrou à bride Hex Nylock, 3/8″-24, ZN GRF Nut, Hex Flanged Nylock, 3/8″-24, ZN GRF 2 14800471_00 Rondelle, plate 3/8″, ID.406″, OD.812″, TH0.065″, Gr8, ZA Washer, Flat 3/8″, ID.406″, OD.812″, TH0.065″, Gr8, ZA 2 14800204_00 Vis, tête bombée, Hex Drive, M6-1, LG 20mm, SS Screw, Button Head, Hex Drive, M6-1, LG 20mm, SS 2 14802272_00 Rondelle M6, 18 mm OD 1,4 mm – 1,8 mm THK. acier inoxydable Washer M6, 18 mm OD 1.4 mm – 1.8 mm THK. stainless steel 2 14800269_00 Écrou à bride, Filet déformé, M6x1, ZN, CL10 Flanged nut, Distorted Thread, M6x1, ZN, CL10 2 Identifiant / Identifier Description Description : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 3 of 23 A Douille 9/16’’ 9/16″ socket B Douille 15/64″ ou 6mm. 15/64″ or 6mm socket C Ensemble de clés hexagonales et/ou ensemble de douilles et clés à rochet Hex key set and/or ratchet and socket set D Clé dynamométrique (50-200 lb-po / 4-17 lb-ft / 5-23 Nm) Torque wrenchs (50-200 lb-po / 4-17 lb-ft / 5-23 Nm) E Riveteuse a rivet-écrou Lion PN : 0-0801 Lion PN Metric kit : 0-0802 Rivet nut tool Lion PN : 0-0801 Lion PN Metric kit : 0-0802 F Pince à dénuder Wire tripper G Pince coupante Wire cutter CONSOMMABLES/CONSUMABLES Lion PN / Lion PN Description Description 12610487_01 Graisse, Graisse Diélectrique NYOGEL 760G*L Grease, Grease Dielectric NYOGEL 760G*L 12610342_00 Master Disconnect Switch, 300 A, Red/Black, On/Off (Si necessaire) Master Disconnect Switch, 300 A, Red/Black, On/Off (If required) N/A Attache Autobloquante (toutes grandeurs) Cable Tie (all sizes) : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 4 of 23 1. PRÉREQUIS / PREREQUISITES A Positionnez le véhicule dans un endroit plat et sécuritaire puis mettez le véhicule au point mort. Position the vehicle in a safe, level area and put the vehicle in neutral. B Appliquez le frein de stationnement et tournez le commutateur d’allumage à la position ‘’OFF’’ (Fermé) en vous assurant de garder la clé de contact dans un endroit sécuritaire pendant le travail. Apply the parking brake and turn the ignition switch to the “OFF” position, making sure to keep the ignition key in a safe place while working. C Tournez le commutateur de sécurité de basse-tension à la position ‘’OFF’’ (Fermé). Turn the low-voltage safety switch to the “OFF” position. D Cadenassez-le selon la procédure de cadenassage en vigueur. Lock it out according to the lockout procedure in effect. E Installez les cales de roues sur la roue avant droite. Chock the front right wheel. D D C C E : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 5 of 23 2. Démontage du coupe-circuit / Removal of the kill switch A Dirigez-vous vers le panneau d’accès aux batteries 12 V. Go to the 12 V battery access panel. B Retirez le la porte du boitier à batteries. Remove the battery box cover. C Dévissez les supports à batteries avec les boulons papillons, encerclés en bleu. Unscrew the battery holders with the thumb bolts, circled in blue. D Retirez les capuchons des connections électriques de la batterie. Avec une douille 9/16 ou une clé, dévissez les connections électriques des deux batteries (4 boulons), encerclés en vert. Remove the electrical connection caps from the battery. Using a 9/16 socket or wrench, unscrew the electrical connections for both batteries (4 bolts), circled in green. 2. Démontage du coupe-circuit (suite) / Removal of the kill switch (continued) Note Il est FORTEMENT recommandé de ne pas incliner les batteries 12V au plomb, s’assurer que les batteries sont manipulées à l’horizontale. It STRONGLY recommended to not tilt the 12 V lead batteries. Make sure that they are handled in the horizontal position. D Retirez les deux batteries du compartiment à batterie. Remove both batteries from the battery compartment. E Localisez les boulons de l’interrupteur du coupe-circuit qui sont situés en arrière de celui-ci. Locate the bolts for the kill switch switch which are located behind it. B D D D D C C : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 6 of 23 F Déposez les boulons et les rondelles et jetez-les. Remove the bolts and washers and dispose of them. Note Si besoin, faute d’accès aux boulons, vous pouvez déposer le coupe-circuit et la remonter ultérieurement. If needed, you can remove the kill switch and reinstall it later. G Retirez les deux câbles électriques connectés à l’interrupteur du coupe-circuit. Remove the two electrical cables connected to the kill switch’s switch. Note Un câble est connecté du coupe-circuit vers la borne positive de la batterie 12V. L’autre câble va du coupe-circuit vers le PDC, qui situé sous le capot, du côté gauche du véhicule. A cable is connected from the kill switch to the positive connector of the 12 V battery, and the other cable is connected from the kill switch to the PDC, which is located on the left side of the vehicle, under the hood. Note Dans la Figure H on voit le câble à enlever dans la méga-fuse au PDC qui est à la 4eme position. In Figure H is shown the cable to be removed that links the Mega-fuse to the PDC’s 4th position. H Suivez chacun des deux câbles électriques jusqu’à l’autre extrémité, puis déconnectez-les et ensuite retirez-les. Follow each of the two electrical cables to their other extremity, disconnect them and remove them. E E Vue arrière Vue arrière / Rear view/ Rear view 2 2 écrous /rondelles cachés sur écrous /rondelles cachés sur la face opposéela face opposée 2 2 nutsnuts/washers /washers hidden on hidden on opposite face.opposite face. Mega fuse/ Mega fuse/ H H Câble à enlever Câble à enlever F : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 7 of 23 2. Démontage du coupe-circuit (suite) / Removal of the kill switch (continued) Note Il est primordial d’inspecter l’état du coupe-circuit avant de le réinstaller. It is essential to inspect the condition of the kill switch before reinstalling it. I Enlever le cadenas qui a été placé sur le coupe circuit avant de procéder à l’inspection. Vérifiez l’interrupteur du coupe-circuit pour toutes anomalies telles que : • Décoloration des boulons • Signe de fonte du plastique de l’interrupteur • Tirer légèrement sur les pôles de l’interrupteur pour s’assurer qu’il n’y a aucun mouvement. • Vérifiez si l’interrupteur peut être actionner de la position ON et OFF sans aucune résistance. Si une quelconque anomalie est détectée (même mineure soit-elle), changez le coupe-circuit par un nouveau coupe-circuit 12610342_00. Remove the lock that was placed on the killswitch prior to performing inspection Inspect the kill switch switch for any anomaly such as: • Bolt discoloration • Signs of melting of the plastic switch • Pull slightly on the bolts to ensure that there is no movement. • Verify that the interrupter can be be turned from the ON and OFF position without any resistance. If any anomaly is detected (even minor), change the circuit interrupter with a new kill switch 12610342_00. E E Incorrecte Incorrecte :: la la surface arrière et surface arrière et décolorédécoloréee Correct Correct :: Ni le Ni le boulon et ni la boulon et ni la surface de plastique surface de plastique arrière décoloré.arrière décoloré. : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 8 of 23 3. INSTALLATION DU SUPPORT CÂBLE / CÂBLE BRACKET INSTALLATION A Localisez la paroi supérieure du compartiment à batterie qui est situé juste en arrière de la roue avant du côté de l’opérateur. Locate the top portion of the battery compartment, which is located right behind the front wheel, on the operator’s side. B Percez deux trous sur la paroi supérieure du boitier à batterie comme illustré sur le schéma de la Figure B. Pierce two holes on the top portion of the battery compartment, as illustrated in Figure B. C Insérez des rivets-écrou 14802388 X2 du coté intérieur de la paroi supérieure du boitier à batteries dans les trous percés précédemment puis écrasez les rivets-écrous sur une longueur 12 mm avec une riveteuse a rivet-écrou comme montré dans la Figure C. Insert two rivet-nuts 14802388 in the previously pierced holes from the interior of battery comparment’s upper wall, and, using a rivet-nut rivet gun as shown in Figure C, crimp the rivet-nuts to a length of 12 mm. C C Paroi supérieure / Paroi supérieure / Top panelTop panel B B Extérieur du Extérieur du véhiculevéhicule / / exterior of the vehicleexterior of the vehicle Vue de dessus / Top view Vue de dessus / Top view : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 9 of 23 A A Face du haut du coupe Face du haut du coupe–circuit/Kill switch top side circuit/Kill switch top side B B C C 4. Installation du support à porte-fusible / Fuse holder bracket installation Note Avant d’installer le harnais 12801272_01, installez d’abord le support du portes fusibles C139. Before installing the 12801272_01 harness, first install the fuse holder C139. A Percez deux trous de diamètre 6mm comme montré dans la Figure A en prenant comme repère la face du haut du support coupe-circuit. Pierce two 6-mm holes as shown in Figure A by taking the top of the kill switch support as a position indicator. B Positionnez le support porte-fusible C139 sur la paroi latérale gauche du boitier à batteries 12 V du coté intérieur à l’emplacement suivant dessous le coupe-circuit dans la boite à batteries 12 V comme montré dans la Figure B. Position the fuse holder support C139 on the left lateral wall inside of the 12 V battery compartment, underneath the kill switch as shown in Figure B. C Installez le support du porte fusible et fixez-le avec 2X vis M6 14800204_00, 2X rondelles 14802272_00 et 2X écrous 14800269_00 avec rondelles orientées côté de l’écrou. Install the fuse holder support and attach it using 2 screws M6 14800204_00, 2 washers 14802272_00 and 2 nuts 14800269_00 with washers on the nut side. D Serrez les vis à un couple de 55 livres par pouce avec une clé dynamométrique. Tighten the screws to 55 lb-in with a torque wrench. Vue de dessous / Bottom view Vue de dessus / Top view : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 10 of 23 5.Connexion du harnais BT dans le boitier à batteries 12V /LV harness connection in the 12V batteries box Note2 Référez-vous à la Figure B/J pour exécuter les étapes 6.B à 6. J Refer to Figure B/J to execute steps 6.B to 6. J. A Dirigez-vous vers le boitier à batteries 12 V . Go towards the 12 V battery compartment. B Installez le nouveau câble du coupe-circuit 12810599_01 avec la cosse 90 degrés à la position de l’ancien câble qui se rend du coupe-circuit (la borne de droite du coupe-circuit) vers la borne positive de la batterie 12V Note : Le câble doit passer proche du plafond du boitier a batteries comme montré dans l’image B Install the new kill switch cable 12810599_01 with the terminal at a 90-degree angle from the previous cable that originates from the kill switch (the right connector of the kill switch) to the positive connector of the 12 V battery Note: The cable must pass close to the ceiling of the battery box as shown in the image B. B-1 Insérez une rondelle 14800471_00 et un écrou 14810832_00 puis vissez-le à un couple de 80 livres-pouce du côté du coupe-circuit. Insert a washer 14800471_00 and a nut 14810832_00. Finally tighten it to a torque of 80 lb-inch on the kill switch side. C Installez le nouveau câble du coupe-circuit 12801306_01 avec la cosse 90 degrés à la position de l’ancien câble qui se rend du coupe-circuit (borne de gauche) vers le boitier à fusibles puis ajoutez une rondelle 14800471_00 et un écrou 14810832_00 puis vissez-le à un couple de 80 livres-pouce du côté du coupe-circuit et à un couple de 96 à 120 lb-po (8 à 10 lb-pi) du côté du boitier à fusibles. Install the new kill switch cable 12801306_01 with the terminal at a 90-degree angle from the previous cable that originates from the kill switch (the left terminal of the kill switch) to the fuse box and add a washer 14800471_00 and a nut 14810832_00 and tighten it to a torque of 80 lb-in., on the kill switch side, and to a torque of 96-120 lb-in. (8 to 10 lb-ft.) on the fuse box side. D Ouvrez un collier en P 14811062 et insérez le dans le câble 12810599_01 connecté à la borne de droite du coupe-circuit et un Collier en P 14800662 du câble 12801306_02 connectée à la borne de gauche du coupe-circuit. Note : Assurez-vous que la partie plate du collier en P se trouve du côté de dessus. Open a P clamp 14811062 and insert it in the cable 12810599_01 that is connected to the right terminal of the kill switch and open another P clamp and insert it in the cable 12801306_02 that is connected to the left terminal of the kill switch. Note: Make sure that the flat portion of the P clamp is positioned at the top. E Positionnez et ajustez les deux colliers en P pour les mettre vis-à-vis du trou précédemment percé sur la paroi du haut du boitier à batterie le plus proche du coupe-circuit. Position and adjust the two P clamps to align them with the previously pierced hole at the top of the battery compartment that is the closest to the kill switch. F Insérez un boulon 14802621 avec une rondelle 14802186 dans les colliers en P du bas vers le haut puis insérez un espaceur 14801308 et insérez le tout dans la rivet-écrou la plus proche du coupe-circuit. Insert a bolt 14802621 with a washer 14802186 in the P clamp from the bottom up, and insert a spacer 14801308, and insert this assembly in the rivet-nut the closest to the kill switch. G Ouvrez un collier en P 14800662 et insérez la dans le gros câble du coupe-circuit 12801306_01 Open a P clamp 14800662 and insert it in the big cable of the kill switch 12801306_01 that is : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 11 of 23 connecté à la borne de gauche du coupe-circuit (en regardant de l’extérieur du véhicule). Note : Assurez-vous que la partie plate du Collier en P se trouve du côté de dessus. connected to the left connector of the kill switch (looking from the outside of the vehicle). Note: Make sure that the flat portion of the P clamp is positioned at the top. H Positionnez et ajustez le collier en P pour le mettre vis-à-vis du trou précédemment percé sur la paroi du haut du boitier à batterie le plus éloigné du coupe-circuit. Position and adjust the P clamp to align it with the previously pierced hole of the upper wall of the battery compartment, the furthest away from kill switch. I Insérez un boulon 14802612 avec une rondelle 14802186 dans les colliers en P du bas vers le haut puis insérez un espaceur 14801308 et insérez le tout dans la rivet-écrou la plus éloignée du coupe-circuit. Insert a bolt 14802612 with a washer 14802186 in the P clamps from the bottom up, and insert a spacer 14801308, and insert this assembly in the rivet-nut that is the furthest away from the kill switch. J Vissez et serrez les deux boulons à un couple de 80 livre-pouce. Screw and tighten both bolts to a torque of 80 in-lbs K Replacez les deux batteries 12 V dans leur compartiment. Return both 12 V batteries to their compartment. L Appliquez une couche de Nyogel 760 gr 12610487_01 anticorrosif sur toute la surface des boulons et écrous du coupe-circuit comme montré dans la Figure B/J. Apply a coat of anticorrosion Nyogel 760 gr 12610487_01 on the entire surface of the bolts and nuts of the kill switch as illustrated in Figure B/J. M Connectez le câble avec le terminal 12 VLug du harnais 12801272_01 et l’autre extrémité du câble 12810599_01 du coupe-circuit sur la borne positive de la batterie 12 V. Appliquer un couple de 195in-lbs (22Nm) sur la 12V lug pour attache les deux cables. Connect the cable with the 12 V terminal lug of the harness 12801272_01 and the other side of the cable 12810599_01 of the kill switch to the positive connector of the 12 V battery. Torque the 12V lug to 195in-lbs (22Nm) to attach both cables. Borne de gauche/ Borne de gauche/leftleft terminalterminal Sens de la vue Sens de la vue / / direction of direction of viewview Borne de droite/ Borne de droite/right terminalright terminal B/J B/J B B : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 12 of 23 B B//JJ Cable Cable 12810599_0112810599_01 vers la vers la borne de droiteborne de droite\\ cable cable 12810599_0112810599_01 to the to the right right connectorconnector Cable Cable 12801306_02 12801306_02 vers la borne de vers la borne de gauchegauche\\ cable cable 12801306_0212801306_02 to to the left connectorthe left connector D D–LL : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 13 of 23 A A Sortie au firewall/Firewall exit Sortie au firewall/Firewall exit Vue de dessous/bottom view Vue de dessous/bottom view Routage du câble Routage du câble/cable rooting/cable rooting Vue de section/section view Vue de section/section view 6.Connection du harnais BT dans le PDC / LV harness connection in the PDC A Localisez le PDC qui est situé sous le capot, du côté de l’opérateur. Locate the PDC with is under the hood, on the operator’s side. Note Ne pas mettre d’attaches autobloquantes qui seront installées lors du routage final. Do not put zip ties. They will be installed at the final routing. B Acheminez le harnais 12801272_01 du boitier de batteries 12V vers le PDC en sortant par le trou à l’arrière de la boite à batterie, passant par-l’arrière de la boîte à batterie, puis à travers l’espace entre le firewall et la fibre de verre puis jusqu’au PDC comme montré sur les images A et B. Route the 12801272_01 harness from the 12V battery box to the PDC by exiting through the hole in the back of the battery box, through the back of the battery box, then through the gap between the firewall and the fiberglass and then to the PDC as shown in images A and B. Note Si le véhicule est un LionC Gen1 passez aux étapes R à D1. If the vehicle is a LionC Gen1, proceed to steps R to D1 C Ouvrez le PDC et déconnectez les connecteurs C112 (connecteur noir) et le connecteurs C110 (connecteur gris). Open the PDC and disconnect the C112 connector (black connector) and the C110 connector (gray connector). D Referez-vous au schéma de l’image D, et exécutez les étapes 6E à 6P. Refer to the diagram in image D, and follow steps 6E to 6P Sortie du boitier/Battery box exit : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 14 of 23 B B Sortie du Sortie du boitierboitier 12V/12V/ A cette étape ne pas m A cette étape ne pas mettre ettre d’attache autobloquantesd’attache autobloquantes C : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 15 of 23 D D 6. Connection du harnais LV dans le PDC / LV harness connection in the PDC Note Le fil FL-1 doit être raccordé avec les fils SP1505 et SP1506 qui sont branchés dans le C112 😀 et C112 :E. The FL-1 wire must be spliced with the SP1505 and SP1506 wires that are plugged into the C112:D and C112:E. E Retirer les fils du C112 😀 et C112 :E Remove the wires from C112:D and C112:E F Couper le fil au niveau du terminal pour enlever le terminal Cut the wire at the terminal to remove the terminal G Raccordez les fils sur le FL-1 en utilisant un raccord 12610352_00 Connect the wires to the FL-1 using a 12610352_00 connector H Installez des cavity plugs 12600703_00 dans les C112 😀 et C112 :E Install cavity plugs 12600703_00 in the C112:D and C112:E Note Le fil FL-2 doit être raccordé avec le fil SP050 qui est branché dans le C112 :C. The FL-2 wire must be spliced with the SP050 wire that is plugged into the C112:C. I Retirer le fil du C112 :C Remove the wire from C112:C J Couper le fil au niveau du terminal pour enlever le terminal Cut the wire at the terminal to remove the terminal : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 16 of 23 E E Cable C11 Cable C112 2 \\ C11C1122 cablecable F F–LL K Raccorder le fil sur FL-2 en utilisant un raccord 12610353_00 Connect the wire to FL-2 using a 12610353_00 fitting L Installez une cavity plug 12600703_00 dans le C112 :C Install a cavity plug 12600703_00 in the C112:C 6. Connection du harnais LV dans le PDC / LV harness connection in the PDC (suite) Note Le fil FL-3 doit être raccordé avec le fil SP051 qui est branché dans le C110 :A. Wire FL-3 must be spliced with wire SP051 which is plugged into C110:A. M Retirer le fil du C110 :A Remove the wire from C110:A N Couper le fil au niveau du terminal pour enlever le terminal Cut the wire at the terminal to remove the terminal O Raccorder le fil sur FL-3 en utilisant un raccord 12610353_00 Splice the wire to FL-3 using a 12610353_00 fitting P Installez une cavity plug 12600703_00 dans le C110 :A Install a cavity plug 12600703_00 in the C110 :A Q Fixer le harnais en utilisant des attaches autobloquantes pour l’attacher au câble 12801306_01 Secure the harness using self-locking clips to attach it to the wire 12801306_01 : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 17 of 23 M M Cable C11 Cable C110 0 \\ C11C1100 cablecable N N–PP Q Q : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 18 of 23 6. Connection du harnais LV dans le PDC / LV harness connection in the PDC (Suite) Note Les étapes R à D1 sont uniquement pour le LionC Gen1. Steps R to D1 are for LionC Gen1 only. Note1 Referez-vous aux images des étapes 6.C à 6.Q pour exécuter les étapes R à D1 Refer to the images in steps 6.C through 6.Q to perform steps R to D1 Note2 Le fil FL-1 doit être raccordé avec les fils SP1505 et SP1506 qui sont branchés dans S-J4-item-33 Wire FL-1 must be spliced with wires SP1505 and SP1506 that are plugged into S-J4-item-33 R Retirer les fils du S-J4-item-33:C et S-J4-item-33 :L Remove the wires from the S-J4-item-33:C and S-J4-item-33:L S Couper le fil au niveau du terminal pour enlever le terminal Cut the wire at the terminal to remove the terminal T Raccordez les fils sur le FL-1 en utilisant un raccord 12610352_00 Connect the wires to the FL-1 using a 12610352_00 connector U Installez des cavity plugs 12600703_00 dans les S-J4-item-33:C et S-J4-item-33 : L Install cavity plugs 12600703_00 in the S-J4-item-33:C and S-J4-item-33:L Note Le fil FL-2 doit être raccordé avec le fil SP050 qui est branché dans le S-J6-item-31 The FL-2 wire must be spliced with the SP050 wire that is plugged into the S-J6-item-31 V Retirer le fil du S-J6-item-31: G Remove the wire from the S-J6-item-31: G W Couper le fil au niveau du terminal pour enlever le terminal Cut the wire at the terminal to remove the terminal X Raccorder le fil sur FL-2 en utilisant un raccord 12610353_00 Splice the wire onto FL-2 using a 12610353_00 fitting Y Installez une cavity plug 12600703_00 dans le S-J6-item-31: G Install a cavity plug 12600703_00 in the S-J6-item-31: G Note3 Le fil FL-3 doit être raccordé avec le fil SP051 qui est branché dans le S-J5-item-32. The FL-3 wire must be spliced with the SP051 wire that is plugged into the S-J5-item-32. Z Retirer le fil du S-J5-item-32: J Remove the wire from the S-J5-item-32: J A1 Couper le fil au niveau du terminal pour enlever le terminal Cut the wire at the terminal to remove the terminal B1 Raccorder le fil sur FL-3 en utilisant un raccord 12610353_00 Splice the wire onto FL-3 using a 12610353_00 connector C1 Installez une cavity plug 12600703_00 dans le S-J5-item-32: J Install a cavity plug 12600703_00 in the S-J5-item-32: J D1 Fixer le harnais en utilisant des attaches autobloquantes pour l’attacher au câble 12801306_01 vous référer aux images R et S pour plus de détails. Secure the harness using tie wraps to attach it to the wire 12801306_01 refer to images R and S for reference pictures. : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 19 of 23 Q Q R R S S Attach 12801272 to Attach 12801272 to 1281030612810306 Attach Attach 1280127212801272 to to 1281030612810306 : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 20 of 23 B B B B Avant du véhicule / Avant du véhicule / front of front of the the vehiclevehicle Centre du véhicule / Centre du véhicule / Center of vehicleCenter of vehicle 7.Reconnection des cables et du porte fusible dans le boitier à batteries 12V / Reconnecting the cables and fuse holder in the 12V battery box A Dirigez-vous vers le boitier à batteries 12V et replacer les deux batteries dans leur compartiment. Move to the 12V battery box and replace the two batteries in their compartment. B Installer le connecteur C139 du harnais 12801272_01 sur son support dans la boîte à batterie comme montré dans l’image B. Install the C139 connector of the 12801272_01 harness on its bracket in the battery box as shown in image B. 7.Reconnection des cables et du porte fusible dans le boitier à batteries 12V / Reconnecting the cables and fuse holder in the 12V battery box (suite) C Reconnectez tous les câbles précédemment connectés au batteries 12V sauf les câbles retirés du coupe-circuit. Reconnect all cables previously connected to the 12V batteries except the cables removed from the circuit breaker D Serrez-les connections aux bornes des batteries à un couple de 195livre-pouce (22Nm) et assurez-vous de connecter la borne positive en premier puis suivie de la borne négative. the tightening torque for the battery terminals is 195in-lbs (22Nm) and remember to put the positive back on first followed by the negative. : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 21 of 23 F F E E E Assurez-vous que les cosses des batteries sur les 4 bornes de la batterie sont également serrées à 195in-lbs (22Nm), comme indiqué sur l’image E. Ensure that the wire connection lugs on the 4 battery posts are also tightened to 195in-lbs (22Nm), as shown on image E. F Pendant l’installation, notez la position des attaches des batteries comme indiqué sur l’image F, et serrez à la main les écrous à oreilles jusqu’à ce qu’ils soient bien serrés, essayez de déplacer les batteries et resserrez si nécessaire. During installation, note the position of the battery clips as shown in image F, and hand tighten the wing nuts until they are tight, try to move the batteries and re-tighten if necessary. G Dirigez-vous au PDC et assurez-vous que tous les connecteurs sont installés et connectés puis fermez le PDC. Go to the PDC and unsure all connectors are installed and connected, then close the PDC H Fixer le harnais 12801272_01 sur le câble 12801306_01 le long de leur passage ensemble, puis fixer le harnais 12801272_01 sur le harnais 12800441_01 en dessous du PDC Attach the 12801272_01 harness to the 12801306_01 cable along their path together, then attach the 12801272_01 harness to the 12800441_01 harness below the PDC : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 22 of 23 8.Test / Test Note Pour valider les correctifs il est primordial d’effectuer des tests ci-dessous avec un véhicule immobile et loin de toute circulation routière. To validate the corrections, it is essential to carry out a tests bellow with a stationary vehicle and far from any road traffic. A Mettez l’interrupteur extérieur sur la position “OFF” ; Turn the outside switch to the “OFF” position; B Sans clé dans le contact, appuyez sur la pédale de frein, assurez-vous que la pompe de freinage d’urgence s’active (bruit de pompe hydraulique). Faire le même test avec le klaxon, appuyer sur le bouton du klaxon et confirmer qu’il produit du son. With no key in the ignition, press on the brake pedal, make sure the emergency brake pump activates (hydraulic pump noise). Perform the same tests for the horn, press horn button and confirm is horn is heard. C Arrêtez d’appuyer sur la pédale de frein et le bouton du klaxon, assurez-vous que la pompe de freinage d’urgence s’arrête et que le klaxon arrête de fonctionner. Stop pressing the brake pedal and horn button, make sure the emergency brake pump stops and the horn sound stops. D Mettez l’interrupteur extérieur sur la position “ON” ; Turn the outside switch to the “ON” position; E Sans clé dans le contact, appuyez sur la pédale de frein, assurez-vous que la pompe de freinage d’urgence s’active (bruit de pompe hydraulique). Faire le même test avec le klaxon, appuyer sur le bouton du klaxon et confirmer qu’il produit du son. With no key in the ignition, press on the brake pedal, make sure the emergency brake pump activates (hydraulic pump noise). Perform the same tests for the horn, press horn button and confirm is horn is heard. F Arrêtez d’appuyer sur la pédale de frein et le bouton du klaxon, assurez-vous que la pompe de freinage d’urgence s’arrête et que le klaxon arrête de fonctionner. Stop pressing the brake pedal and horn button, make sure the emergency brake pump stops and the horn sound stops. G Tournez la clé de contact sur la position “ON”. Assurez-vous que le véhicule est allumé et qu’aucun message d’erreur n’apparaît à l’écran. Turn the ignition key to the “ON” position. Make sure the vehicle is turned on and that no error messages appear on the screen H Tournez la clé de contact sur la position “START” et assurez-vous que la haute tension est activée et qu’aucun message d’erreur n’apparaît à l’écran. Turn the ignition key to the “START” position and make sure that the high voltage is activated and that no error message appears on the screen I Coupez le contact. Turn off the ignition. J Enlevez les cales, mettez les circuits électriques sur ”ON” (ouvert) puis conduisez l’autobus et validez que tout est fonctionnel. Remove the chocks, turn the electrical circuits to ”ON” (Open) then drive the bus and validate that everything is functional. : BS0223 FO-0022 Rappel-Bulletin de Service / Recall-Service Bulletin Page 23 of 23 REVISION MODIFICATION RESPONSABLE INGÉNIERIE # REV DATE Ex : Création 00 AAAA/MM/JJ Création Karim Bouchebaba William Prud’homme 01 AAAA/MM/JJ 02 AAAA/MM/JJ APPROBATION Date : 2022/01/05 Karim Bouchebaba Concepteur mécanique – Documentation technique
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IMPORTANT SAFETY RECALL January 5th, 2022 «Corporate_name» «Address» «City» «ProvState» «Zip_Code» «Country» Important Safety Recall 21V968 This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Title 49, United States Code Chapter 301, administered by the National Highway Traffic Safety Administration. This is to inform you that your vehicle may contain a defect that could affect the safety of a person. Description of the vehicle (s) affected by the defect Make Lion Model Lion C Model Year 2017 to 2021 Vehicle Identification Number (VIN) See Appendix A Recall number issued by NHTSA 21V968 Description of the defect A failure of the 12V circuit breaker kill switch could result in the loss of steering assist and a loss of braking capability (primary and secondary systems). Lion has found a series of corrections to apply to the 12V circuit to improve the vehicle safety. Corrective measures and precautions Important note: An instruction is attached to this communication to validate the status of the 12V circuit breaker switch, please follow the instruction. According to this instruction, if an anomaly is detected, you must contact The Lion Electric immediately at this toll-free number: 1 855 546-6706 ext.: 229 and not use the identified vehicle. Following your report of the defect to the Lion Electric, they will contact you shortly to determine the date to perform the service. IMPORTANT SAFETY RECALL Contact For any question, do not hesitate to contact the service department at the 1 855 546-6706 ext.: 229. 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, as applicable. To learn more about what you need to do to obtain reimbursement, contact Customer Support above. We estimate the time to perform the labor required to correct the defect to be approximately 1 hour. If you no longer own this vehicle, please contact Lion to provide the new owner information. Lion will then contact the new owner. If you are the lessor of this vehicle, please forward a copy of this notice to the lessee within 10 days to comply with federal regulations. After contacting the Lion Electric Company’s customer support number, if you still are not able to have the safety defect remedied without charge and within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1–888–327–4236 (TTY: 1–800–424–9153); or go to http://www.safercar.gov, if you believe that Lion Electric has failed or is unable to remedy the defect or noncompliance without charge. Our priority is to always provide you with a product of the highest quality and security levels. We apologize for the inconvenience and would like to thank you for your trust and valuable cooperation. Khalid Hammani Quality Director
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-968 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lion Electric Company Submission Date : FEB 02, 2022 NHTSA Recall No. : 21V-968 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Lion Electric Company Address : 921, chemin de la Riviere-du-Nord Saint-Jerome, Quebec, Canada 00 J7Y 5G2 Company phone : 1-855-546-6706 Population : Number of potentially involved : 168 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2017-2021 Lion LionC Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : We have determined the number of impacted vehicles with our database and these are all LionC vehicles produced and sold in the United States Production Dates : APR 01, 2016 – DEC 10, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Failure of the 12V circuit breaker switch could result in loss of steering assist and loss of braking capability (primary and secondary systems). Lion has identified a series of corrections to the 12V circuit to improve the vehicle safety. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : The identified failure is evaluated as one that could occur a few times in the life of a vehicle impacted by this defect. The probability is therefore qualified as “unlikely”. However, the impacts of such a failure could represent a human safety issue and a risk of injury and/or death in the event of complete loss of steering and brake assist, if the driver fails to use the emergency hand brake. In the event of such a failure, the hand brake system remains functional and fully operational. Description of the Cause : NR Part 573 Safety Recall Report 21V-968 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : September 2, 2021: LionC accident on King Street in Sherbrooke. September 30: Vehicle inspection by all parties involved at 241 Léger Street in Sherbrooke. October 6: EPN 835 (Engineering Project Numbers) openening. October 8: Beginning of the procedure of the preliminary tests. November 7: Attempts to reproduce the cause of the accident at the vehicular level. November 26: Identification of the present fix in the test series and validation. To date, the investigation is still ongoing to identify the cause of the accident. Description of Remedy : Description of Remedy Program : All costs will be paid by the Lion Electric Company,We will send teams to do the repairs at the customers How Remedy Component Differs from Recalled Component : NR Part 573 Safety Recall Report 21V-968 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : This recall fix will be implemented on all production vehicles as of December 27 Recall Schedule : Description of Recall Schedule : Lion plans to send the defect notice to owners of affected vehicles and affected individuals beginning December 20, 2021. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : JAN 07, 2022 – JAN 14, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-968 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lion Electric Company Submission Date : DEC 14, 2021 NHTSA Recall No. : 21V-968 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Lion Electric Company Address : 921, chemin de la Riviere-du-Nord Saint-Jerome, Quebec, Canada 00 J7Y 5G2 Company phone : 1-855-546-6706 Population : Number of potentially involved : 170 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2017-2021 Lion LionC Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : We have determined the number of impacted vehicles with our database and these are all LionC vehicles produced and sold in the United States Production Dates : APR 01, 2016 – DEC 10, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Failure of the 12V circuit breaker switch could result in loss of steering assist and loss of braking capability (primary and secondary systems). Lion has identified a series of corrections to the 12V circuit to improve the vehicle safety. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : The identified failure is evaluated as one that could occur a few times in the life of a vehicle impacted by this defect. The probability is therefore qualified as “unlikely”. However, the impacts of such a failure could represent a human safety issue and a risk of injury and/or death in the event of complete loss of steering and brake assist, if the driver fails to use the emergency hand brake. In the event of such a failure, the hand brake system remains functional and fully operational. Description of the Cause : NR Part 573 Safety Recall Report 21V-968 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : September 2, 2021: LionC accident on King Street in Sherbrooke. September 30: Vehicle inspection by all parties involved at 241 Léger Street in Sherbrooke. October 6: EPN 835 (Engineering Project Numbers) openening. October 8: Beginning of the procedure of the preliminary tests. November 7: Attempts to reproduce the cause of the accident at the vehicular level. November 26: Identification of the present fix in the test series and validation. To date, the investigation is still ongoing to identify the cause of the accident. Description of Remedy : Description of Remedy Program : All costs will be paid by the Lion Electric Company,We will send teams to do the repairs at the customers How Remedy Component Differs from Recalled Component : NR Part 573 Safety Recall Report 21V-968 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : This recall fix will be implemented on all production vehicles as of December 27 Recall Schedule : Description of Recall Schedule : Lion plans to send the defect notice to owners of affected vehicles and affected individuals beginning December 20, 2021. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : DEC 27, 2021 – JAN 10, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-968 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lion Electric Company Submission Date : MAR 01, 2022 NHTSA Recall No. : 21V-968 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Lion Electric Company Address : 921, chemin de la Riviere-du-Nord Saint-Jerome, Quebec, Canada 00 J7Y 5G2 Company phone : 1-855-546-6706 Population : Number of potentially involved : 168 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2017-2021 Lion LionC Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : We have determined the number of impacted vehicles with our database and these are all LionC vehicles produced and sold in the United States Production Dates : APR 01, 2016 – DEC 10, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Failure of the 12V circuit breaker switch could result in loss of steering assist and loss of braking capability (primary and secondary systems). Lion has identified a series of corrections to the 12V circuit to improve the vehicle safety. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : The identified failure is evaluated as one that could occur a few times in the life of a vehicle impacted by this defect. The probability is therefore qualified as “unlikely”. However, the impacts of such a failure could represent a human safety issue and a risk of injury and/or death in the event of complete loss of steering and brake assist, if the driver fails to use the emergency hand brake. In the event of such a failure, the hand brake system remains functional and fully operational. Description of the Cause : NR Part 573 Safety Recall Report 21V-968 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : Master Disconnect Switch Component Description : Manual Battery Disconnect Switch Component Part Number : 75920 Supplier Identification : Component Manufacturer Name : Littlelfuse Address : 8755 West Higgins Road, Suite 500 Chicago Illinois 60631 Country : United States Chronology : September 2, 2021: LionC accident on King Street in Sherbrooke. September 30: Vehicle inspection by all parties involved at 241 Léger Street in Sherbrooke. October 6: EPN 835 (Engineering Project Numbers) openening. October 8: Beginning of the procedure of the preliminary tests. November 7: Attempts to reproduce the cause of the accident at the vehicular level. November 26: Identification of the present fix in the test series and validation. To date, the investigation is still ongoing to identify the cause of the accident. Description of Remedy : Description of Remedy Program : All costs will be paid by the Lion Electric Company,We will send teams to do the repairs at the customers How Remedy Component Differs from Recalled Component : The remedy involves an update of our methods not of the component itself Part 573 Safety Recall Report 21V-968 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : This recall fix will be implemented on all production vehicles as of December 27 Recall Schedule : Description of Recall Schedule : Lion plans to send the defect notice to owners of affected vehicles and affected individuals beginning December 20, 2021. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : JAN 07, 2022 – JAN 14, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-968 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lion Electric Company Submission Date : FEB 14, 2022 NHTSA Recall No. : 21V-968 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Lion Electric Company Address : 921, chemin de la Riviere-du-Nord Saint-Jerome, Quebec, Canada 00 J7Y 5G2 Company phone : 1-855-546-6706 Population : Number of potentially involved : 168 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2017-2021 Lion LionC Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : We have determined the number of impacted vehicles with our database and these are all LionC vehicles produced and sold in the United States Production Dates : APR 01, 2016 – DEC 10, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Failure of the 12V circuit breaker switch could result in loss of steering assist and loss of braking capability (primary and secondary systems). Lion has identified a series of corrections to the 12V circuit to improve the vehicle safety. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : The identified failure is evaluated as one that could occur a few times in the life of a vehicle impacted by this defect. The probability is therefore qualified as “unlikely”. However, the impacts of such a failure could represent a human safety issue and a risk of injury and/or death in the event of complete loss of steering and brake assist, if the driver fails to use the emergency hand brake. In the event of such a failure, the hand brake system remains functional and fully operational. Description of the Cause : NR Part 573 Safety Recall Report 21V-968 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : Master Disconnect Switch Component Description : Manual Battery Disconnect Switch Component Part Number : 75920 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : September 2, 2021: LionC accident on King Street in Sherbrooke. September 30: Vehicle inspection by all parties involved at 241 Léger Street in Sherbrooke. October 6: EPN 835 (Engineering Project Numbers) openening. October 8: Beginning of the procedure of the preliminary tests. November 7: Attempts to reproduce the cause of the accident at the vehicular level. November 26: Identification of the present fix in the test series and validation. To date, the investigation is still ongoing to identify the cause of the accident. Description of Remedy : Description of Remedy Program : All costs will be paid by the Lion Electric Company,We will send teams to do the repairs at the customers How Remedy Component Differs from Recalled Component : NR Part 573 Safety Recall Report 21V-968 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : This recall fix will be implemented on all production vehicles as of December 27 Recall Schedule : Description of Recall Schedule : Lion plans to send the defect notice to owners of affected vehicles and affected individuals beginning December 20, 2021. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : JAN 07, 2022 – JAN 14, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-968 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lion Electric Company Submission Date : DEC 22, 2021 NHTSA Recall No. : 21V-968 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Lion Electric Company Address : 921, chemin de la Riviere-du-Nord Saint-Jerome, Quebec, Canada 00 J7Y 5G2 Company phone : 1-855-546-6706 Population : Number of potentially involved : 170 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2017-2021 Lion LionC Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : We have determined the number of impacted vehicles with our database and these are all LionC vehicles produced and sold in the United States Production Dates : APR 01, 2016 – DEC 10, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Failure of the 12V circuit breaker switch could result in loss of steering assist and loss of braking capability (primary and secondary systems). Lion has identified a series of corrections to the 12V circuit to improve the vehicle safety. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : The identified failure is evaluated as one that could occur a few times in the life of a vehicle impacted by this defect. The probability is therefore qualified as “unlikely”. However, the impacts of such a failure could represent a human safety issue and a risk of injury and/or death in the event of complete loss of steering and brake assist, if the driver fails to use the emergency hand brake. In the event of such a failure, the hand brake system remains functional and fully operational. Description of the Cause : NR Part 573 Safety Recall Report 21V-968 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : September 2, 2021: LionC accident on King Street in Sherbrooke. September 30: Vehicle inspection by all parties involved at 241 Léger Street in Sherbrooke. October 6: EPN 835 (Engineering Project Numbers) openening. October 8: Beginning of the procedure of the preliminary tests. November 7: Attempts to reproduce the cause of the accident at the vehicular level. November 26: Identification of the present fix in the test series and validation. To date, the investigation is still ongoing to identify the cause of the accident. Description of Remedy : Description of Remedy Program : All costs will be paid by the Lion Electric Company,We will send teams to do the repairs at the customers How Remedy Component Differs from Recalled Component : NR Part 573 Safety Recall Report 21V-968 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : This recall fix will be implemented on all production vehicles as of December 27 Recall Schedule : Description of Recall Schedule : Lion plans to send the defect notice to owners of affected vehicles and affected individuals beginning December 20, 2021. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : JAN 07, 2022 – JAN 14, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-968 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lion Electric Company Submission Date : DEC 22, 2021 NHTSA Recall No. : 21V-968 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Lion Electric Company Address : 921, chemin de la Riviere-du-Nord Saint-Jerome, Quebec, Canada 00 J7Y 5G2 Company phone : 1-855-546-6706 Population : Number of potentially involved : 170 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2017-2021 Lion LionC Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : We have determined the number of impacted vehicles with our database and these are all LionC vehicles produced and sold in the United States Production Dates : APR 01, 2016 – DEC 10, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Failure of the 12V circuit breaker switch could result in loss of steering assist and loss of braking capability (primary and secondary systems). Lion has identified a series of corrections to the 12V circuit to improve the vehicle safety. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : The identified failure is evaluated as one that could occur a few times in the life of a vehicle impacted by this defect. The probability is therefore qualified as “unlikely”. However, the impacts of such a failure could represent a human safety issue and a risk of injury and/or death in the event of complete loss of steering and brake assist, if the driver fails to use the emergency hand brake. In the event of such a failure, the hand brake system remains functional and fully operational. Description of the Cause : NR Part 573 Safety Recall Report 21V-968 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : September 2, 2021: LionC accident on King Street in Sherbrooke. September 30: Vehicle inspection by all parties involved at 241 Léger Street in Sherbrooke. October 6: EPN 835 (Engineering Project Numbers) openening. October 8: Beginning of the procedure of the preliminary tests. November 7: Attempts to reproduce the cause of the accident at the vehicular level. November 26: Identification of the present fix in the test series and validation. To date, the investigation is still ongoing to identify the cause of the accident. Description of Remedy : Description of Remedy Program : All costs will be paid by the Lion Electric Company,We will send teams to do the repairs at the customers How Remedy Component Differs from Recalled Component : NR Part 573 Safety Recall Report 21V-968 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : This recall fix will be implemented on all production vehicles as of December 27 Recall Schedule : Description of Recall Schedule : Lion plans to send the defect notice to owners of affected vehicles and affected individuals beginning December 20, 2021. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : JAN 07, 2022 – JAN 14, 2022 * NR – Not Reported
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SEOCONTENT-END