51-1485 – Loose Wiring May Cause Fire – 2022 Coachmen Catalina, Aurora, Apex, Freedom Express, Spirit, Work N Play, Forest River XLR Toy Hauler, Vengeance, Sabre, Cherokee, & Cardinal Travel Trailers & Fifth Wheel Trailers

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March 8, 2022 NHTSA CAMPAIGN NUMBER: 22V135000

Loose Wiring May Cause Fire

Loose wires may contact each other and cause an electrical short, increasing the risk of a fire.

 

NHTSA Campaign Number: 22V135

Manufacturer Forest River, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 1,009

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2022 Coachmen Catalina, Aurora, Apex, Freedom Express, Spirit, Work N Play, Forest River XLR Toy Hauler, Vengeance, Sabre, Cherokee, and Cardinal travel trailers and fifth wheels. The wire cord that connects to the back of the 50AMP shore power inlet may be loose.

 

Remedy

Dealers will replace the shore cord inlet, free of charge. Owner notification letters were mailed April 5, 2022. Owners may contact the following customer service numbers: Forest River 1-574-825-4995; Catalina & Aurora 1-574-825-8657; APEX 1-574-825-8205; Freedom Express & Work n Play 1-574-825-6302; Cardinal 1-574-296-7700; Cherokee and Vengeance 1-260-499-2100; Sabre 1-574-642-2100; and XLR 1-574-642-0432. Forest River’s number for this recall is 51-1485.

 

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.

 


ZH Brothers International, the manufacturer and importer of Epicord Part No. 93379, 50A Shore Power Inlets, has initiated a safety recall of a specific population of these products. We have enclosed a copy of ZH Brothers’ Amended Defect Information Report (DIR), which was filed with the National Highway Traffic Safety Administration (NHTSA) on March 26, 2022 (Recall No. 22E023). As we advised you in our “Product Containment Request” dated March 15, 2022, these parts were received into Patrick Distribution’s stock on February 1 and February 9, 2022, and supplied to you between February 2 and February 22, 2022.

ZH Brothers is instructing customers to conduct a torque check on the lug bolts of inlets from the suspect lots. If proper torque cannot be confirmed, the inlet should be replaced.

We are working with ZH Brothers to facilitate this recall campaign. Accordingly, you should submit your claims for parts and labor through the existing Patrick Distribution warranty claims process.

If you have any questions, please contact Orrin Price at (574) 612-6271 or priceo@patrickind.com.

 


RECALL 22V135 / 2022-106 REMEDY INSTRUCTIONS

Make(s): MANY, SEE BELOW
Model(s): MANY, SEE BELOW
Model Year(s): 2022
Repair Code: RC-003-01-00-004163
Allotted Time: .25 HRS.
Inspection Code: RC-003-05-00-004162
Allotted Time: .25 HRS
Concern:
If the lugs on the shore cord inlet are loose and wire(s) dislodge, the wire(s) may contact/short/arc. This may lead to a fire and personal injury.
Photo(s) Required: YES, PRIOR
Prior Authorization Required: NO
Part(s) Kit Number: 93379
Part(s) Return: NO

 

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.

 

CERTAIN MODELS:

APEX – APTT256BHS, APTT265RBSS, APTT266BHS & APTT293RLDS AURORA – AART29ATH, AART29QBS, AART31KDS & AART34BHTS CARDINAL – CAF320RLX, CAF320RLX-W, CAF380RLX & CAF380RLX-W CATALINA – ACAT293QBCKLE, ACAT293QBCKLE-W, ACAT303QBCKLE, ACAT303QBCKLE-W, ACAT303RKDSLE, ACAT303RKDSLE-W, ACAT30THS, ACAT30THS-W, ACAT323BHDSCKLE, ACAT323BHDSCKLE-W, ACAT343BHTSLE & ACAT343BHTSLE-W

CHEROKEE – ACKT264DBH, ACKT264DBHBL, ACKT274BRB, ACKT274BRBBL, ACKT274RK, ACKT274RKBL, ACKT274WK, ACKT274WKBL, ACKT294BH, ACKT294GEBG, ACKT294KM, ACKT29QB, ACKT29RRTBL, ACKT29TE, ACKT29TEBL, ACKT304BH, ACKT304RK, ACKT306MM, ACKT306MMBL, ACKT324TS, CCKT25RRT, CCKT25RRTBL, CCKT26MBRR, CCKT27DBH, CCKT27RR, CCKT27RRBL, CCKT29BRB, CCKT29BRBBL, CKF287BH-75, CKF291RL-75, CKF321BH-75, CKF327MB-75, CKF3550SUITE-75, CKF3660SUITE-75, CKF3770SUITE-75, CKF3880SUITE-75, CKF3990SUITE-75, CKT26DBH-L-76, CKT26RK-L-76, CKT26RL-L-76, CKT28FK-L-76, CKT30DBH-L-76, CKT30RDB-L-76 & CKT33BH-L-76

CHEROKEE TOY HAULER – CKF310PACK10, CKF315PACK12, CKF325PACK13 & CKF345PACK14.5

FREEDOM EXPRESS – FET29SE-320 SABRE – SRF36BHQ-C, SRF37FLH-C, SRF37FLL-C & SRF38DBQ-C SPIRIT – SBT2557RB VENGEANCE – VGF351G2-81, VGF371A13-81, VGF383G2-81 & VGF4007VG2-81 WORK AND PLAY – WPT23LT & WPT27LT XLR TOY HAULER – XLT27LRLE-79, XLT27QB-79B, XLT29QBX-79B & XLT31QB-79B

 

INSPECTION/REMEDY INSTRUCTIONS ARE LOCATED IN DEALER CONNECT!

 

STEP 1: PLEASE FOLLOW THE INSPECTION, AND, IF REQUIRED, THE REMEDY INSTRUCTIONS FROM PATRICK   INDUSTRIES.

 

NOTE: IF A REPLACEMENT INLET IS REQUIRED, TAKE PHOTOS OF THE REMOVED INLET AND EMAIL PATRICK INDUSTRIES AT p100returns@patrickind.com OR CALL PATRICK INDUSTRIES AT (574) 970-8282 TO REQUEST A REPLACEMENT 50AMP INLET.

 

CLAIM THE INSPECTION OR REPAIR CODE THROUGH FOREST RIVERS’ DEALERCONNECT.

 

****Product Safety Notice***

 

March, 14, 2022

We have determined that a potential defect which relates to the safety of the end consumer exists in your unit.

If you are reading this then your manufacturer has already notified you of a potential issue with your unit. Refer to your Original Equipment Manufacturer’s notice for specific vehicle identification number (VIN#) and please follow instructions included below.

 

EPICORD 50A POWER INLET REVIEW PROCEDURE

STEP 1.  Locate the 50A inlet on the side or rear of the RV in question to determine what brand of power inlet is installed.  If the inlet is EPICORD brand and looks like the below picture, proceed to step 2. If the Inlet on your unit looks different than the picture below, a substitution may have been made at the OEM and no further action is needed.

 

STEP 2.  Move to the inside of the RV to locate the load center.  Once the load center is located, turn the 50A main breaker to the OFF positon.

 

STEP 3.  After turning the 50A main breaker to the OFF position, remove the four mounting screws located on the face of the inlet and pull the inlet out of the RV wall.

SAVE THESE SCREWS AS THEY WILL BE NEEDED TO REINSTALL THE INLET.

 

STEP 4. After pulling the inlet out of the RV wall, remove the two screws on the inside of the inlet. This will allow you to remove the housing from the back side of the inlet.

 

STEP 5. Unscrew the strain relief on the back of the housing to allow room for the wires to move.

 

STEP 6.  First make a visual inspection of wires. Make sure they are seated properly within the lugs so that there is no sheathing or wire jacket under the lugs preventing proper securement. Once visual inspection looks correct, check EACH lug for proper torque setting of 20 in/lb. If torque specification is met, on EACH lug then skip to steps 13-16 for reinstallation.

****WARNING****

If torque specification cannot be met, the part is defective and needs replaced. This will be evident by the torque screwdriver slipping off of the lug prior to reaching the specified 20in/lbs.

If the Inlet is deemed defective, please proceed to step 7 for replacement instructions.

 

STEP 7. Loosen each of the lugs which are securing the four wires into the body of the device. Pull the wires out of the device and through the strain relief located on the back side of the device.

 

STEP 8. Cut the 6/3 wire so that you are starting with fresh wire leads.

 

STEP 9.  Strip back 1 1/2” of exterior sheathing detail (A) for ease of wire hook up. Inspect each wire for any signs of bare copper around sheathing. If any signs of bare copper make sure to cut out bad wire and start process over again. Straighten out the individual wires to orient them roughly in a straight line.   Strip back conductor jacket back 3/4” in detail (B) from wire for proper application.

 

STEP 10.   After all four wires have been properly prepared, loosen the strain relief before running wires through the back side of the housing utilizing the round hole in the back body of the inlet.  * DO NOT TIGHTEN CONNECTOR ONTO THE WIRE YET. *

 

STEP 11.   Insert each individual wire into its appropriate connection.

a. Black wire goes into the hole marked black.

b. White wire goes into the hole marked white.

c. Red wire goes into the hole marked red.

d. Bare copper wire (ground) goes into the hole marked green.

 

STEP 12.   Insert each wire completely into its appropriate lug and screw it down making sure there is no sheathing or conductor jacket under the lugs. Torque each connection lug to the manufacturer’s recommended setting of 20 inch pounds.

 

STEP 13.  Slide the back body of the device down the wire and align properly with the back of inlet.

 

STEP 14.  Reinstall the 2 screws to secure housing to inlet and tighten the rear strain relief.

 

STEP 15. Re-insert the EPICORD 50A inlet back into the wall of the RV and secure using the four screws removed in step 4 above.  Please be sure to clear away any old caulking and reseal as per manufacturers standard operating procedure.

 

STEP 16. Proceed inside the unit and turn the 50A main breaker located in the load center to the ON position.  You have now completed the reinstallation of your 50A EPICORD inlet.

 


This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This notice is also sent in accordance with the requirements of the United States’ National Traffic and Motor Vehicle Safety Act. Forest River has decided that a defect, which relates to the motor vehicle safety, exists in certain 2022 Catalina, Aurora, Cherokee, APEX, Freedom Express, Work n’ Play and XLR Travel Trailers, as well as certain 2022 Cardinal, Cherokee Toy Hauler, Sabre and Vengeance Fifth Wheel 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 lugs on the shore cord inlet may not be tightened properly.

 

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

If the lugs on the shore cord inlet are loose and wire(s) dislodge, the wire(s) may contact/short/arc. This may lead to a fire and 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, which will include inspection of the lugs torque and wiring at the shore cord inlet and replace if necessary. It is preferable if you have your selling dealership perform the remedy to tighten the lugs on the shore cord inlet’s wiring. 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. 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 coachmenrv.com/dealer-locator for dealer locations.

 

HOW LONG WILL THE REMEDY PROCESS TAKE?

The estimated time of repair is .5 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:

Sabre
Forest River, Inc.
Attn: Warranty Manager
2577 E Kercher Rd
Goshen, IN 46528

Cardinal
Forest River, Inc.
Attn: Warranty Manager
3603 S. Nappanee St.
Elkhart, IN 46517

Cherokee and Vengeance
Forest River, Inc.
Attn: Warranty Manager
1500 N Detroit St.
LaGrange, IN 46761

Catalina, Aurora, APEX, Freedom Express and Work n Play
Forest River, Inc.
Attn: Warranty Manager
423 N Main St.
Middlebury, IN 46540

XLR
Forest River, Inc.
Attn: Warranty Manager
2421 Century Dr.
Goshen, IN 46528

 


Chronology :

On February 25, 2022, during a routine Corporate Quality Inspection of the manufacturing plant it was found that the 6AWG wire that connects to the rear of the 50AMP shore power inlet may be loose. During investigation ending on March 3, 2022, it was determined by the partner supplier that a substitution of material (due to lack of material) to make the lug which was a harder material than specified. This caused the stamping of the “Phillips Head” not be at the required specified depth.

On March 4, 2022, Forest River’s Corporate Recall Committee voted to recall.

On March 14, 2022 The quantity of vehicles was updated due to a clerical error from 991 to 1,009. All Models and Quantities on the attached document are correct.

 


11 Affected Products

Vehicles

MAKE MODEL YEAR
COACHMEN APEX 2022
COACHMEN AURORA 2022
COACHMEN CATALINA 2022
COACHMEN FREEDOM EXPRESS 2022
COACHMEN SPIRIT 2022
COACHMEN WORK AND PLAY 2022
FOREST RIVER CARDINAL 2022
FOREST RIVER CHEROKEE 2022
FOREST RIVER SABRE 2022
FOREST RIVER VENGEANCE 2022
FOREST RIVER XLR TOYHAULER 2022

 


10 Associated Documents

Defect Notice 573 Report

RCLRPT-22V135-9446.PDF 220.444KB

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Recall 573 Report – 3/14/2022

RCLRPT-22V135-7115.PDF 220.534KB

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Recall Acknowledgement

RCAK-22V135-6909.pdf 688.402KB

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Remedy Instructions and TSB

RCRIT-22V135-8832.pdf 577.64KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V135-6062.pdf 177.702KB

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Miscellaneous Document – Patrick Distribution – Letter Notifying Customers of ZH Brothers Recall

RMISC-22V135-1707.pdf 450.468KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V135-1097.pdf 207.857KB

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Recall Quarterly Report #1, 2022-2

RCLQRT-22V135-8022.PDF 211.126KB

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Recall Quarterly Report #2, 2022-3

RCLQRT-22V135-2307.PDF 211.222KB

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Recall Quarterly Report #3, 2022-4

RCLQRT-22V135-3009.PDF 211.315KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V135&docType=RCL

 


 

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