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March 9, 2022 NHTSA CAMPAIGN NUMBER: 22V139000
Output Inductor May Contact Frame
An electric arc increases the risk of a fire.
NHTSA Campaign Number: 22V139
Manufacturer Maintainer Corporation of Iowa, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 17
Summary
Maintainer Corporation of Iowa, Inc. (Maintainer) is recalling certain 2021-2022 Maintainer crane equipped truck bodies with a Miller Enpak. The output inductor may contact the frame of the Enpak, causing an electric arc.
Remedy
Dealers will install a new cross bracket, free of charge. Owner notification letters were mailed on March 21, 2022. Owners may contact Maintainer’s customer service at 1-800-831-8588.
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.
EnPak A60 Output Inductor
The output inductor on EnPak A60 models listed above was manufactured incorrectly, which causes it to contact a metal air baffle within the power module assembly.
To correct this issue, install kit 291874 and follow the instructions.
Replacing Inductor Bracket
Stop engine and let cool.
Disconnect the battery cables from the truck battery.
1 Top Door Prop
2 White End Panel
3 Lower Cross Bracket
4 Inductor
Ensure the top door prop is bolted in place.
This is used to support the inverter.
Remove all screws on the white end panel.
Fold panel down.
Remove two screws on each end of the lower cross bracket. Remove and discard bracket.
Install new cross bracket with cutout. Make sure there is at least 0.1 in. (2.5 mm) clearance between the inductor and the bracket.
Straighten bracket if twisted.
Reinstall end panel.
Chronology :
We were notified from Miller Electric through certified mail on 3/05/22 with a serial number listing of all affected Enpak A60GBH units that the output inductor may come in contact with the frame of the machine due to a nonconformant part. Through a serial number search within Maintainers ERP system, we were able to identify and locate all the affected Enpak units and trucks that some had been installed on.
This recall submission is including the 17 Maintainer trucks with the installed Miller Enpak units that were shipped to dealers or customers prior to the Miller notification. Miller will be covering these repair costs and supplying the Service Kits and field repair instructions for Maintainer dealers to perform.
Miller Electric Techs arrived on Maintainer premises March 16th and 17th to perform their Service Memo 1287 repairs on 11 additional Enpak units that had been installed on Maintainer trucks and held on our grounds through our yellow tag process prior to shipping to our dealers and customers. Miller covered these costs.
Miller Electric performed on March 16th and 17th their Service Memo 1287 repairs on an additional 28 Enpak units that were in our inventory at the Maintainer facility before being installed on Maintainer trucks. Miller covered these costs.
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
MAINTAINER | CRANE W/ SERVICE BODY | 2021-2022 |
10 Associated Documents
Part 577 Owner Notification Envelope
RONE-22V139-3638.pdf 243.983KB
Remedy Instructions and TSB
RCRIT-22V139-6740.pdf 1890.618KB
Remedy Instructions and TSB
RCRIT-22V139-1178.pdf 184.549KB
Defect Notice 573 Report
RCLRPT-22V139-8798.PDF 214.072KB
Recall Acknowledgement
Recall 573 Report- 04/08/2022
RCLRPT-22V139-6847.PDF 214.297KB
Recall 573 Report-05/10/2022
RCLRPT-22V139-7918.PDF 214.719KB
Recall Quarterly Report #1, 2022-1
RCLQRT-22V139-4922.PDF 211.129KB
Recall Quarterly Report #2, 2022-2
RCLQRT-22V139-2055.PDF 239.413KB
Recall Quarterly Report #3, 2022-3
RCLQRT-22V139-7812.PDF 211.312KB
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=22V139&docType=RCL
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SEOCONTENT-START
1. Safety Symbol Definitions DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE – � Indicates statements not related to personal injury. Indicates special instructions. CALIFORNIA PROPOSITION 65 WARNINGS WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov Beware of electric shock from wiring. Stop engine and disconnect negative (-) cable from battery before installing this kit. Reinstall all panels and covers. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. Moving parts can injure. Keep away from fans, belts and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Keep hands, hair, loose clothing, and tools away from moving parts. Before working on hydraulic system, turn off and lockout/tagout unit, release pressure, and be sure hydraulic pressure cannot be accidentally applied. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when servicing is finished and before starting engine. Hot parts and fluid can cause severe burns. Do not touch hot parts bare handed or allow hot fluid to contact skin. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. Hydraulic equipment can injure or kill. Incorrect installation or operation of this unit could result in equipment failure and personal injury. Only qualified persons should install, operate, and service this unit according to its Owner’s Manual, industry standards, and national, state, and local codes. Do not exceed the rated output or capacity of the hydraulic pump or any equipment in the hydraulic system. Design hydraulic system so failure of any hydraulic component will not put people or property at risk. Before working on hydraulic system, turn off and lockout/tagout unit, release pressure, and be sure hydraulic pressure cannot be accidentally applied. Do not work on hydraulic system with unit running unless you are a qualified person and following the manufacturer’s instructions. Do not modify or alter hydraulic pump or manufacturer supplied equipment. Do not disconnect, disable, or override any safety equipment in the hydraulic system. Use only components/accessories approved by the manufacturer. Keep away from potential pinch points or crush points created by equipment connected to the hydraulic system. Do not work under or around any equipment that is supported only by hydraulic pressure. Properly support equipment by mechanical means. Hydraulic fluid can injure or kill. Before working on hydraulic system, turn off and lockout/tagout unit, release pressure, and be sure hydraulic pressure cannot be accidentally applied. Relieve pressure before disconnecting or connecting hydraulic lines. Check hydraulic system components and all connections and hoses for damage, leaks, and wear before operating unit. Wear protective equipment such as safety glasses, leather gloves, heavy shirt and trousers, high shoes, and a cap when working on hydraulic system. Use a piece of paper or cardboard to search for leaks—never use bare hands. Do not use equipment if leaks are found. HYDRAULIC FLUID is FLAMMABLE—do not work on hydraulics near sparks or flames; do not smoke near hydraulic fluid. Reinstall doors, panels, covers, or guards when servicing is finished and before starting unit. If ANY fluid is injected into the skin or body seek medical help immediately. ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2022-02 Have only trained and qualified persons install, operate, or service this unit. Call your distributor or the equipment manufacturer if you do not understand the directions. For WELDING SAFETY and EMF information, read Owner’s Manual. All directions are given as facing front panel. Keep hardware for reuse. Staple these instructions inside Owner’s Manual. FIELD INSTRUCTIONS 2022-02 FORM: F291875A Inductor Bracket Replacement Kit 291874 For EnPak A60 F291875 Page 2 2. Tools Needed OM-222 Page 1 torque wrench socket wrench drill hammer awl file crimper paintbrush feelergauge flashlight ruler toothbrush greasegun qtip (swab) vicegrip handream punch filterwrench strapwrench airgun solvent pinextractor eprompuller pipewrench torque screwdriver 3/8, 1/2 in. OM-222 Page 1 NGO’s tools/ flathead philips head wrench knife heavy-duty workclamp light-duty workclamp wirecutter frontcutter allen_set needlenose steelbrush nutdriver chippinghammer stripcrimp socket wrench drill hammer awl file crimper paintbrush feelergauge flashlight ruler greasegun vicegrip handream punch filterwrench airgun solvent pinextractor eprompuller pipewrench crescent wrench 3/8 in. glasses hairdryer oilcan filtersocket snapringpliers linepliers pencil rubbergloves weldgloves earmuffs pinextractor2 tip_dress T_allen pinextractor (141761) Needle-Nose Vise Grip Ground Strap 3. Replacing Inductor Bracket 2 1 3 2 3 4 4 Stop engine and let cool. Disconnect the battery cables from the truck battery. 1 Top Door Prop 2 White End Panel 3 Lower Cross Bracket 4 Inductor Ensure the top door prop is bolted in place. This is used to support the inverter. Remove all screws on the white end panel. Fold panel down. Remove two screws on each end of the lower cross bracket. Remove and discard bracket. Install new cross bracket with cutout. Make sure there is at least 0.1 in. (2.5 mm) clearance between the inductor and the bracket. Straighten bracket if twisted. Reinstall end panel.
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Forward to: Service Administration From: Power Systems Division Date: February 24, 2022 Number: 1287 Subject: EnPak A60 Output Inductor Model Stock Number Serial Number Range EnPak A60GB 907813, 907813001 Prior to Serial No. NC080172R EnPak A60GBH 907814, 907814001 EnPak A60GBHW 907815, 907815001 The output inductor on EnPak A60 models listed above was manufactured incorrectly, which causes it to contact a metal air baffle within the power module assembly. Incorrect Assembly (No Clearance) Correct Assembly (With Clearance) To correct this issue, install kit 291874 and follow the instructions. Please contact the Power Systems Division Service Group at 920-735-4505 or psdservice@millerwelds.com if you have any questions. Normal warranty procedures apply. A maximum of 1 hour will be allowed for this repair.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-139 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Maintainer Corporation of Iowa, Inc. Submission Date : MAR 09, 2022 NHTSA Recall No. : 22V-139 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Maintainer Corporation of Iowa, Inc. Address : 1701 2nd Ave. Sheldon IA 51201 Company phone : 712-324-8125 Population : Number of potentially involved : 17 Estimated percentage with defect : 100 % Vehicle Alterer Information : Vehicle 1 : 2021-2022 Maintainer Maintainer crane equiped service/mechanics truck bodies Descriptive Information : The voluntary recall vehicles are 1-ton and 2-ton service bodies of various, optional configurations, but each contains a Maintainer installed Miller Enpak model A60GBH auxiliary power unit. Miller has provided us with a list of serial numbers for all the affected Enpak units. Maintainer performed a part number search within our ERP system to determine which service bodies contained this particular Miller Enpak Model. Production Dates : SEP 17, 2021 – FEB 09, 2022 Description of Defect : Description of the Defect : The service bodies involved in this recall are equipped with a Miller Enpak A60GBH that are installed by Maintainer. Miller Electric has informed us through certified letter and a service memo that the output inductor may contact the frame of the Enpak due to a nonconformant part. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Per Miller Service memo 1287 and field instructions FORM: F291875A contact could occur between the output inductor and the frame potentially causing an electric arc and/or an unintended path for electric current to flow. This creates a risk of fire and damage to the Enpak and service body. This would only occur while the Enpak is operating and not while the service body is traveling down the road. Description of the Cause : Per Miller Service memo 1287 and field instructions FORM: F291875A, the output inductor on Enpak A60 models were manufactured incorrectly, which causes it to contact a metal air baffle within the power module assembly. Identification of Any Warning that can Occur : There could potentially be no warning if the output inductor contacts the frame of the Enpak while it is operating. Part 573 Safety Recall Report 22V-139 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name : Miller Enpak A60GBH Component Description : Auxiliary power unit Component Part Number : 907814 and 907815 Supplier Identification : Component Manufacturer Name : Miller Electric Manufacturing Co. Address : 1635 W. Spencer St. P.O. Box 1079 Appleton Wisconsin 54912-1079 Country : United States Chronology : We were notified from Miller through certified mail on 3/05/22 with a listing of all affected models that the output inductor may come in contact with the frame of the machine due to a nonconformant part. Description of Remedy : Description of Remedy Program : Maintainer has been made aware of a remedy through Miller service memo 1287. Miller has also provided field repair instructions along with an install repair kit (291874). Maintainer will coordinate the repairs with Miller by providing dealer and customer locations. These repairs will be free of charge to our Dealers and Customers. How Remedy Component Differs from Recalled Component : Please see the service memo no. 1287 and field instructions FORM: F291875A provided by Miller electric. The remedy will be the removal and Installation of a new cross bracket per Miller’s installation kit 291874 called out in FORM: F291875A. Identify How/When Recall Condition was Corrected in Production : All affected Maintainer service trucks in production containing the Enpak will have the remedy applied to the Enpak prior to final shipment. All completed service trucks on the Maintainer premises with the Enpak’s and all Enpak’s in our inventory have been yellow tagged and will be repaired here on site by trained Miller Enpak personnel. Miller is scheduled to perform the repairs on 3/16/22. Part 573 Safety Recall Report 22V-139 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Recall Schedule : Description of Recall Schedule : The notification letters will be mailed according to our specified dealer and owner begin and end dates. Planned Dealer Notification Date : MAR 21, 2022 – APR 29, 2022 Planned Owner Notification Date : MAR 21, 2022 – APR 29, 2022 Purchaser Information : The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : Address : Country : Company Phone : * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-139 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Maintainer Corporation of Iowa, Inc. Submission Date : MAY 10, 2022 NHTSA Recall No. : 22V-139 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Maintainer Corporation of Iowa, Inc. Address : 1701 2nd Ave. Sheldon IA 51201 Company phone : 712-324-8125 Population : Number of potentially involved : 17 Estimated percentage with defect : 100 % Vehicle Alterer Information : Vehicle 1 : 2021-2022 Maintainer Maintainer crane equiped service/mechanics truck bodies Descriptive Information : The voluntary recall vehicles are 1-ton and 2-ton service bodies of various, optional configurations, but each contains a Maintainer installed Miller Enpak model A60GBH auxiliary power unit. Miller has provided us with a list of serial numbers for all the affected Enpak units. Maintainer performed a part number search within our ERP system to determine which service bodies contained this particular Miller Enpak Model. Production Dates : SEP 17, 2021 – FEB 09, 2022 Description of Defect : Description of the Defect : The service bodies involved in this recall are equipped with a Miller Enpak A60GBH that are installed by Maintainer. Miller Electric has informed us through certified letter and a service memo that the output inductor may contact the frame of the Enpak due to a nonconformant part. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Per Miller Service memo 1287 and field instructions FORM: F291875A contact could occur between the output inductor and the frame potentially causing an electric arc and/or an unintended path for electric current to flow. This creates a risk of fire and damage to the Enpak and service body. This would only occur while the Enpak is operating and not while the service body is traveling down the road. Description of the Cause : Per Miller Service memo 1287 and field instructions FORM: F291875A, the output inductor on Enpak A60 models were manufactured incorrectly, which causes it to contact a metal air baffle within the power module assembly. Identification of Any Warning that can Occur : There could potentially be no warning if the output inductor contacts the frame of the Enpak while it is operating. Part 573 Safety Recall Report 22V-139 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name : Miller Enpak A60GBH Component Description : Auxiliary power unit Component Part Number : 907814 and 907815 Supplier Identification : Component Manufacturer Name : Miller Electric Manufacturing Co. Address : 1635 W. Spencer St. P.O. Box 1079 Appleton Wisconsin 54912-1079 Country : United States Chronology : We were notified from Miller Electric through certified mail on 3/05/22 with a serial number listing of all affected Enpak A60GBH units that the output inductor may come in contact with the frame of the machine due to a nonconformant part. Through a serial number search within Maintainers ERP system, we were able to identify and locate all the affected Enpak units and trucks that some had been installed on. This recall submission is including the 17 Maintainer trucks with the installed Miller Enpak units that were shipped to dealers or customers prior to the Miller notification. Miller will be covering these repair costs and supplying the Service Kits and field repair instructions for Maintainer dealers to perform. Miller Electric Techs arrived on Maintainer premises March 16th and 17th to perform their Service Memo 1287 repairs on 11 additional Enpak units that had been installed on Maintainer trucks and held on our grounds through our yellow tag process prior to shipping to our dealers and customers. Miller covered these costs. Miller Electric performed on March 16th and 17th their Service Memo 1287 repairs on an additional 28 Enpak units that were in our inventory at the Maintainer facility before being installed on Maintainer trucks. Miller covered these costs. Part 573 Safety Recall Report 22V-139 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Maintainer has been made aware of a remedy through Miller service memo 1287. Miller has also provided field repair instructions along with an install repair kit (291874). Maintainer will coordinate the repairs with Miller by providing dealer and customer locations. These repairs will be free of charge to our Dealers and Customers. If you have already paid for a remedy (e.g., repair, replacement, etc.) related to the defect described in this notice, you may be eligible for reimbursement of such costs by submitting a reimbursement claim to our customer service department. Reimbursement information document is included in Dealer and customer letters. How Remedy Component Differs from Recalled Component : Please see the service memo no. 1287 and field instructions FORM: F291875A provided by Miller electric. The remedy will be the removal and Installation of a new cross bracket per Miller’s installation kit 291874 called out in FORM: F291875A. Identify How/When Recall Condition was Corrected in Production : All affected Maintainer service trucks in production containing the Enpak will have the remedy applied to the Enpak prior to final shipment. All completed service trucks on the Maintainer premises with the Enpak’s and all Enpak’s in our inventory have been yellow tagged and will be repaired here on site by trained Miller Enpak personnel. Miller is scheduled to perform the repairs on 3/16/22. Recall Schedule : Description of Recall Schedule : The notification letters will be mailed according to our specified dealer and owner begin and end dates. Planned Dealer Notification Date : MAR 21, 2022 – APR 29, 2022 Planned Owner Notification Date : MAR 21, 2022 – APR 29, 2022 Purchaser Information : The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : Address : Country : Company Phone : * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-139 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Maintainer Corporation of Iowa, Inc. Submission Date : APR 08, 2022 NHTSA Recall No. : 22V-139 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Maintainer Corporation of Iowa, Inc. Address : 1701 2nd Ave. Sheldon IA 51201 Company phone : 712-324-8125 Population : Number of potentially involved : 17 Estimated percentage with defect : 100 % Vehicle Alterer Information : Vehicle 1 : 2021-2022 Maintainer Maintainer crane equiped service/mechanics truck bodies Descriptive Information : The voluntary recall vehicles are 1-ton and 2-ton service bodies of various, optional configurations, but each contains a Maintainer installed Miller Enpak model A60GBH auxiliary power unit. Miller has provided us with a list of serial numbers for all the affected Enpak units. Maintainer performed a part number search within our ERP system to determine which service bodies contained this particular Miller Enpak Model. Production Dates : SEP 17, 2021 – FEB 09, 2022 Description of Defect : Description of the Defect : The service bodies involved in this recall are equipped with a Miller Enpak A60GBH that are installed by Maintainer. Miller Electric has informed us through certified letter and a service memo that the output inductor may contact the frame of the Enpak due to a nonconformant part. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Per Miller Service memo 1287 and field instructions FORM: F291875A contact could occur between the output inductor and the frame potentially causing an electric arc and/or an unintended path for electric current to flow. This creates a risk of fire and damage to the Enpak and service body. This would only occur while the Enpak is operating and not while the service body is traveling down the road. Description of the Cause : Per Miller Service memo 1287 and field instructions FORM: F291875A, the output inductor on Enpak A60 models were manufactured incorrectly, which causes it to contact a metal air baffle within the power module assembly. Identification of Any Warning that can Occur : There could potentially be no warning if the output inductor contacts the frame of the Enpak while it is operating. Part 573 Safety Recall Report 22V-139 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name : Miller Enpak A60GBH Component Description : Auxiliary power unit Component Part Number : 907814 and 907815 Supplier Identification : Component Manufacturer Name : Miller Electric Manufacturing Co. Address : 1635 W. Spencer St. P.O. Box 1079 Appleton Wisconsin 54912-1079 Country : United States Chronology : We were notified from Miller through certified mail on 3/05/22 with a listing of all affected models that the output inductor may come in contact with the frame of the machine due to a nonconformant part. Description of Remedy : Description of Remedy Program : Maintainer has been made aware of a remedy through Miller service memo 1287. Miller has also provided field repair instructions along with an install repair kit (291874). Maintainer will coordinate the repairs with Miller by providing dealer and customer locations. These repairs will be free of charge to our Dealers and Customers. If you have already paid for a remedy (e.g., repair, replacement, etc.) related to the defect described in this notice, you may be eligible for reimbursement of such costs by submitting a reimbursement claim to our customer service department. Reimbursement information document is included in Dealer and customer letters. How Remedy Component Differs from Recalled Component : Please see the service memo no. 1287 and field instructions FORM: F291875A provided by Miller electric. The remedy will be the removal and Installation of a new cross bracket per Miller’s installation kit 291874 called out in FORM: F291875A. Part 573 Safety Recall Report 22V-139 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : All affected Maintainer service trucks in production containing the Enpak will have the remedy applied to the Enpak prior to final shipment. All completed service trucks on the Maintainer premises with the Enpak’s and all Enpak’s in our inventory have been yellow tagged and will be repaired here on site by trained Miller Enpak personnel. Miller is scheduled to perform the repairs on 3/16/22. Recall Schedule : Description of Recall Schedule : The notification letters will be mailed according to our specified dealer and owner begin and end dates. Planned Dealer Notification Date : MAR 21, 2022 – APR 29, 2022 Planned Owner Notification Date : MAR 21, 2022 – APR 29, 2022 Purchaser Information : The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : Address : Country : Company Phone : * NR – Not Reported
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