FL928 – Misrouted Battery Cable May Cause Electrical Short – 2019-2023 Thomas Built Bus HDX School Buses

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

April 22, 2022 NHTSA CAMPAIGN NUMBER: 22V271000

Misrouted Battery Cable May Cause Electrical Short

An electrical short circuit can increase the risk of a fire.

 

NHTSA Campaign Number: 22V271

Manufacturer Daimler Trucks North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 2,943

 

Summary

Daimler Trucks North America, LLC (DTNA) is recalling certain 2019-2023 Thomas Built Bus HDX school buses. The positive battery cable may be routed improperly, allowing it to chafe against the transmission oil cooler hoses, which can cause an electrical short circuit.

 

Remedy

Dealers will inspect and repair the cable routing, as necessary, free of charge. Owner notification letters were mailed January 20, 2023. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL928.

 

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.

 

Check for Daimler Trucks North America Recalls

 


January 2023
FL928 AB
NHTSA #22V-271 (School Bus)
NHTSA #22V-272 (Non-School Bus)
Transport Canada #2022-207 (School Bus)
Transport Canada #2022-208 (Non-School Bus)

 

Subject: TBB HDX Battery Cables

Models Affected: Specific model year 2019-2023 Thomas Built Buses (TBB) HDX model buses, manufactured March 8, 2018, through March 24, 2022.

 

General Information

Daimler Truck North America LLC (DTNA), on behalf of its wholly owned subsidiary, Thomas Built Buses (TBB), has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.

On certain TBB HDX model buses, the battery cables may chafe on the transmission oil cooler hoses, which can cause an electrical short circuit, increasing the risk of a fire.

The battery cable routing will be repaired to prevent contact with the transmission oil cooler hoses.

There are approximately 3,107 vehicles involved in this campaign.

Additional Repairs

Dealers must complete all outstanding Recall and Field Service campaigns prior to the sale or delivery of a vehicle. A Dealer will be liable for any progressive damage that results from its failure to complete campaigns before sale or delivery of a vehicle.

Owners may be liable for any progressive damage that results from failure to complete campaigns within a reasonable time after receiving notification.

 

Routing & Clipping of Power Cables & Transmission Cooler Hoses

NOTE: The affected population for this recall includes vehicles with both Cummins and Detroit Diesel engines, integrated with Allison 2000-series and 3000-series transmissions. The work instructions are predominantly identical for all, unless mentioned otherwise.

1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.

NOTE: The main power disconnect switch (MPDS) is located in the battery box compartment.

2. Turn the MPDS to the OFF position.

3. Disconnect the negative battery cables at the batteries.

4. Open the engine compartment door.

WARNING

Do not use bottle jacks to raise the vehicle. Always use floor jacks. Bottle jacks can slip, allowing the vehicle to fall, which could result in damage to the axle, serious injury, or death.

5. Raise the vehicle, and support it with appropriate jack stands.

NOTE: The transmission cooler hoses and the power cables are located under the rear of the vehicle.

6. Inspect for any blemishes caused due to interference (rubbing) between the power cables and the transmission cooler hoses. See Fig. 1 and Fig. 2.

 

NOTE: Excessive movement of cables and hoses can lead to unwanted cable chaffing due to the vibration.

7. Inspect the power cables and the transmission cooler hoses for excessive movement.

8. Perform a pull-push test to check the amount of movement available to cables. Grip the cables firmly and check for excessive movement, if any.

9. If required, secure the cables with the help of cable ties. For instructions regarding routing and clipping of the cables, see Thomas Built Buses Service Bulletin 00-008 – Routing and Clipping Tips for Extending School Bus Life.

10. Figure 3 and Figure 4 show the ideal positioning of the power cables, clamps, and transmission cooler hoses.

 

11. For vehicles equipped with an Allision 3000-series transmission:
If so equipped, remove and discard the clamp securing the transmission cooler hoses, shown in Fig. 5, by removing the mounting fastener.

 

NOTE: Removing the clamp allows the adjustment of the transmission cooler hoses as instructed in step 12.

12. If necessary, loosen the transmission cooler hose fittings at the transmission, then position the hoses to maintain clearance between the hose and the hose fitting as shown in Fig. 6.

 

13. For vehicles equipped with an Allison 2000-series transmission:
Route and secure the cooler hoses as shown in Fig. 7.

14. If necessary, loosen the transmission cooler hose fittings, and rotate the hoses slightly to ensure zero contact between the power cables and the cooler hoses.

 

15. Connect the negative battery cables at the batteries.

16. Turn the MPDS to the ON position.

17. Start the engine to verify the repair.

 


Chronology :

In mid-February of 2022, DTNA received a report from the field of a potential thermal event on a three-yearold HDX school bus; according to the best of DTNA’s knowledge, no injuries or deaths occurred in this event. DTNA immediately began an investigation into the issue. No additional field reports or warranty claims of fire or similar symptoms were found. In early March of 2022, as soon as reasonably practicable to investigate the vehicle, DTNA’s Cause and Origin investigator examined the suspect bus and determined the origin of the thermal event was likely at the battery cable crossing over the transmission cooler hoses. Within that same month and lasting into April, DTNA began a comprehensive review of warranty data and field reports. Upon reviewing information more closely for this defect, DTNA found 17 total warranty claims ranging from November of 2018 to December of 2020 for the battery cables rubbing or contacting the transmission oil cooler hoses. None of these claims indicated any evidence of a fire or similar thermal event. Nonetheless, in April 2022, out of an abundance of caution DTNA decided to conduct a voluntary recall on certain Thomas Built Bus HDX chassis. There are no injuries or deaths reported. In early May of 2022, in an effort to reduce the administrative burdens and to simply the reporting requirements, DTNA decided to merge recalls FL928 (22V271 – School Bus) and FL929 (22V272 Non School Bus). There are, materially speaking, no differences in the recalls except for the vocations of the population. To further clarify, the newly merged recall population will be designated as FL928A (22V271) for school bus vocations and FL928B (22V272) will be designated for commercial bus vocations. In addition, per a request from the Agency, a more concise description was added to the Involved Components section of the DIR filing.

 


5 Affected Products

Vehicle

MAKE MODEL YEAR
THOMAS BUILT BUSES SAF-T-LINER HDX 2019-2023

 


10 Associated Documents

Recall Acknowledgement

RCAK-22V271-7415.pdf 645.46KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [630.33 KB]

 


Defect Notice 573 Report

RCLRPT-22V271-6386.PDF 214.118KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [209.10 KB]

 


Defect Information Report

RMISC-22V271-2650.pdf 770.048KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [752.00 KB]

 


Amended Defect Information Report

RMISC-22V271-8002.pdf 774.895KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [756.73 KB]

 


Recall 573 Report – May 23, 2022

RCLRPT-22V271-5422.PDF 214.453KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [209.43 KB]

 


Recall 573 Report – June 10, 2022

RCLRPT-22V271-1602.PDF 214.501KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [209.47 KB]

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V271-4414.pdf 119.823KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [117.01 KB]

 


Manufacturer Notices(to Dealers,etc)

RCMN-22V271-3657.pdf 402.816KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [393.38 KB]

 


Manufacturer Notices(to Dealers,etc)

RCMN-22V271-7211.pdf 1035.583KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [0.99 MB]

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V271-6444.pdf 420.234KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [410.38 KB]

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V271&docType=RCL

 


 

Bestseller No. 1
Cartman 4AWG 18-Inch Battery Inverter Cables Set, 4Gauge x 18" (1 Positive & 1 Negtive) for Car, Truck, RV, Solar
  • 4 AWG wire, fits 3/8" stud, SAE 4 GAUGE COPPER
  • Zinc plated 95% copper lugs for superior corrosion and oxidation resistance
  • Better stamping process to improve the current and reduce the resistance.
  • Boat cable wire stays ultra flexible even in the most extreme conditions
  • Heat-resistant up to 105C
Bestseller No. 2
2 AWG Battery Cable 2 Gauge Battery Inverter Cables with 3/8 in Lugs Pure Copper Power Inverter Wire Set for Solar Marine Boat RV Car Motorcycle (1FT, 1 red +1 black cable)
  • 2 gauge battery/welding cable with 3/8 " lugs
  • Can be used on variety of applications, such as automotive, solar, marine, boat, rv, car, motorcycle, etc
  • The battery cable is made of high quality PVC insulation sheath, each cable end is sealed with heat shrink tubing for heat insulation
  • Copper Cable lugs are made of solid copper with a tin plating cover for corrosion protection
  • Please carefully check all the product information to make sure this is the right one you want before placing an order
SaleBestseller No. 3
Energizer Jumper Cables for Car Battery, Heavy Duty Automotive Booster Cables for Jump Starting Dead or Weak Batteries with Carrying Bag Included (16-Feet (6-Gauge)
  • ENERGIZER 16 FEET JUMPER CABLES - 6 Gauge, 16 FT booster battery jumper cables for jump starting a dead or weak battery. Ideal for trucks, SUVs, full-size cars, mid-size cars and small/compact cars
  • THICK VINYL COATING - Includes a strong spring and a comfortable handle for secure placement and easy positioning. Thick vinyl coating for protection against rust and corrosion.
  • CARRYING CASE INCLUDED - Our Energizer jumper cables come with a high-grade travel bag for easy transport and compact storage.
  • TANGLE FREE CCA BOOSTER CABLES - 16 Foot length makes it easy to reach from one car battery to another. Copper clad aluminum cables remains flexible even at -40°C.
  • THE BRAND NAME YOU CAN TRUST - 2 Years Warranty! We are here to power your car battery and truck with our booster jumper cables. We keep you going and going!
Bestseller No. 4
4 AWG Battery Cable 4AWG Gauge Pure Copper Battery Inverter Cables with 3/8 in Lugs Both Ends Power Inverter Wire Set for Automotive Solar Marine Boat RV Car Motorcycle Red and Black (4FT)
  • Fit for Automotive Solar Marine Boat RV Car Motorcycle
  • 4 gauge battery/welding cable with 3/8 " lugs; Battery Cable Length: 4 Feet
  • Package will come with each one of the red and black cable, each cable end is sealed with heat shrink tubing for heat insulation
  • Copper Cable lugs are made of solid copper with a tin plating cover for corrosion protection
  • Please feel free to contact us if you have any questions about our products, your satisfaction would be our greatest motivation
Bestseller No. 5
A ABIGAIL 2 AWG Battery Cable 2AWG Gauge Pure Copper Battery Inverter Cables with 3/8 in Lugs Both Ends Power Inverter Wire Set for Automotive Solar Marine Boat RV Car Motorcycle Red and Black (1FT)
  • 【High Quality】A ABIGAIL battery cables are made of pure copper and tinned copper lugs with superior corrosion and oxidation resistance, which improves the oxidation resistance of copper and maintains its conductivity better.
  • 【Safe & Durable】Premium flexible PVC insulated jacke of battery cables which resists abrasion, waterproof and moisture proof, flame retardant and heat insulation, cable ends are sealed with heat shrink tubing for heat insulation.
  • 【Wide Application】Our positive and negative cables are widely used for car automotive, solar, marine, RV, motorcycle, golf cart, lawn/garden equipment or power inverter batteries, also used for electrical equipment.
  • 【Package Includes】With 2 AWG 12 Inch wire positive (Red) and negative (Black) copper battery cables, 3/8” ring terminal at each end.
  • 【Service】100% satisfaction guarantee, If you have any issues with the part, simply contact customer service for troubleshooting help, parts, replacement, or refund. Our aim is to make you satisfy the parts and the service we provide for you.
Bestseller No. 6
Ampper 5 AWG Battery Cable Set, 20 Inch Copper Power Inverter Cables with Terminals for Car, Vehicle, RV, Solar Application and More (3/8" Ring, 1 Set)
  • Heavy Duty: one set of 5 gauge wire positive (red) and negative (black) copper battery cables, 20 inch for every cable.
  • Easy to Use: each cable have 2 pcs 3/8" (M10) round center hole terminals (already crimped) on both ends, fit for 3/8" (M10) stud.
  • High Quality: copper cables for maximum power transfer, nickel plated copper lugs for superior corrosion and oxidation resistance.
  • Safe & Durable: premium PVC insulated jacket for the cables, cable ends are sealed with heat shrink tubing for heat insulation.
  • Compatible: used for car, vehicle, RV, solar application, boat and more, also used for electrical equipment.
Bestseller No. 7
2 Gauge Battery Cable 2Ft Copper Power Inverter Wire with 3/8" Lugs, Marine Battery Cables for Solar Car Boat RV (2pcs)
  • Sold as a set: 2 gauge battery cable, includes 1x positive(red) and 1x negative(black) cable. Length: 2ft, Gauge: 2AWG, fits 3/8" stud.
  • Durable material: The copper 2 gauge battery cable lugs are tinned coated, well crimped, and utilize a closed end design for corrosion protection.Heat-resistant up to 105C.
  • Easy to connect: These flexible 2 gauge battery cable are made with thinly stranded pure copper, making them easy to handle an install ,It can also be used normally in extreme environments.
  • Use for: Marine battery cables are to withstand harsh environments. 2 gauge battery cable is ideal for various equipments, inverter batteries, cars, solar energy, RV, boat, etc.
  • Warranty: 1 year warranty, 30 days worry-free return, if you have any questions, our customer service will be online 24 hours a day. You can buy our 2 gauge battery cable with confidence.
SaleBestseller No. 8
Smilaxe 4 AWG 18-in Battery Cables Set Pure Copper OFC 4 Gauge Wire with Terminal(1 Positive & 1 Negative), Perfect for Auto, RV/Trailer, Golf Cart, Solar
  • 100% Pure Copper-OFC: These 4 AWG wires made from high-quality imported copper materials and using unique and exquisite craftsmanship.
  • Excellent Conductivity: It has the highest conductivity and thermal conductivity, very low resistance, and can effectively reduce wire losses and improve power transmission efficiency.
  • Good Corrosion Resistance: The oxidation resistance and corrosion resistance of pure copper wire, even in harsh environments such as high temperature and humidity, are not easy to rust and corrode, and can still work stably and reliably.
  • High Plasticity: It can be made into various shapes and sizes of wires according to process requirements, and has high flexibility and torsion. When building various circuits, it can meet your needs and adjust its shape and length.
  • Wide Compatibility: Providing top-notch solutions for your various wiring needs, solar systems, RVs/trailers, boats, Auto and more. If you need other wire gauges or larger quantities, please contact us.
Bestseller No. 9
6 AWG Battery Cables 6 Gauge Battery Power Inverter Cable with 5/16 Inch Tinned Copper Lugs Both Ends for Solar Marine Boat RV Car Motorcycle 2 pcs (3FT)
  • The battery cable replacement is designed to fit for automotive, solar, marine, boat, rv, car, motorcycle, etc
  • Package comes with 2 pcs 6 AWG battery cables, each cable has two 5/16 inch tinned copper ring terminals
  • Wires have 5/16 inch hole allowing it to fit over battery disconnects/switches. The tinned copper wires prevent corrosion and allow for more easily soldering
  • Temperature Range: -45°C to +105°C; Length: 3FT
  • Please carefully check all the product information to make sure this is the right one you want before purchasing
Bestseller No. 10
QIATOL Battery Cable, 8 AWG Battery Cables with Terminals, 2PCS Copper Battery Cables.
  • Premium Material: Battery Cable is made of Copper, which has good electrical conductivity.
  • Wide Applications: Battery Cable can be used for car, vehicle, RV, Truck, solar application, boat, etc.
  • Durable & Safe: The exterior of the Battery Cable is made of premium PVC insulated jacket, which has good thermal insulation.
  • Easy to use: The battery cables with two ring terminals that can be used to connect the battery disconnects/switch. The copper wires prevent corrosion and allow for more easily soldering.
  • What you get: 2PCS Copper Battery Cables.

Last update on 2024-06-11 / Affiliate links / Images from Amazon Product Advertising API

This product presentation was made with AAWP plugin.

 


Leave a Comment

Share to...