Rear Mounted Ultracapacitors Improperly Programmed – 2014-2021 Gillig Low Floor Transit Buses

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

April 25, 2022 NHTSA CAMPAIGN NUMBER: 22V276000

Rear Mounted Ultracapacitors Improperly Programmed

The engine may be started unexpectedly, increasing the risk of injury to anyone nearby the engine compartment during maintenance operations.

 

NHTSA Campaign Number: 22V276

Manufacturer Gillig, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 592

 

Summary

Gillig, LLC (Gillig) is recalling certain 2014-2021 Low Floor transit buses. The rear-mounted ultracapacitors may allow the engine to be started when the master battery disconnect switch is in the “OFF” position.

 

Remedy

Dealers will update the software for the buses equipped with the Vanner Ultracapacitor system, and conduct a hard rewire for the buses equipped with the KBI system, free of charge. Owner notification letters were mailed on June 22, 2022. Owners may contact Gillig’s customer service at 1-510-264-5073 for 1-800-735-1500.

 

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.

 


Gillig has decided that certain model year 2014 through 2021 Low Floor Diesel transit buses, manufactured between 05/21/2014 and 11/10/2021 and equipped with an optional auxiliary energy ultracapacitor feature contain a defect related to motor vehicle safety. In the affected vehicles, a flaw in the design of the controls for the rear chassis mounted ultracapacitors prevents it from detecting that the master battery disconnect switch is in the “OFF” position and may continue to energize the 24-volt battery.

Even with the master battery disconnect switch in the OFF position, if the 24-volt battery is energized and the ignition run switch is turned ON and the engine start button is depressed, the engine may start unexpectedly, posing an increased risk of injury to personnel present or performing maintenance operations in or around the engine compartment at that time.

As a result of the above, GILLIG has decided to voluntarily initiate a safety recall campaign of the vehicle population that may be affected by the issue.

 

What The Issue Is:

With the battery disconnect switch in the “OFF” position, the engine can be started via the ignition run switch and the engine can start unexpectedly and continue to run for several minutes, until the ultracapacitor power is drained.

 

What We Are Asking You To Do:

1. On your Model Year 2014 through 2021 buses equipped with the Vanner supercapacitor system p.n. 13-72000-001/002, GILLIG is asking you to reprogram the supercapacitor controller with a new software update

2. On your Model Year 2019 through 2021 buses equipped with the KBI supercapacitor system p.n. 13-72017-006, GILLIG is asking you to perform a hard wire update of the supercapacitor system

 


Chronology of Defect / Noncompliance Determination

GILLIG produces a limited number of low floor transit buses with rear chassis mounted ultracapacitors which are used as a supplemental source of power during engine starting.  Prior to performing any maintenance operations in the engine compartment of any GILLIG buses (including buses with rear chassis mounted ultracapacitors), there are a series of standard, redundant precautions that are required to be followed to prevent the engine from being started while maintenance personnel are in the vicinity of the engine.  Initially, the ignition select switch in the rear of the bus should be placed in an OFF position.  In addition, users are instructed to attach a “Do Not Operate” tag on the engine start switches and controls.  These redundant, independent precautions are supposed to take place prior to starting any maintenance on the bus.  Finally, users are instructed before starting the vehicle to ensure all personnel are safely clear of the bus.

 

In November 2020, a GILLIG Field Service Representative at a customer location for an unrelated issue was advised by the customer that it was possible on their buses with a rear chassis mounted ultracapacitor to start the buses with the master battery disconnect switch in the OFF position.  The GILLIG representative inspected several of the customers buses with a Vanner model rear chassis mounted ultracapacitor and was eventually able to confirm that the bus engine could be started from the front of the bus, even though the bus main battery was turned off.  Gillig, Vanner and the customer worked through an iterative process over the next few months, to develop a solution for this issue.  In March 2021, Gillig loaded new software onto three of the customer’s buses to understand whether the software would ensure the ultracapacitor contactors remain deenergized and in an open state when the main bus battery is in the OFF position.  In August 2021, Gillig received a report from a separate customer with low floor buses that use a different type of rear chassis mounted ultracapacitor (KBI model) stating that it was possible to start the bus with the master battery disconnect switch in the OFF position.  Gillig began to investigate this customer’s report and in an abundance of caution disabled the ultracapacitor start feature in all buses at this customer’s location.  Notably, neither customer described the circumstances in which they observed that the engine could be started and neither reported that the engine had actually been started when personnel were present in the vicinity of the engine compartment.

 

In early to mid-September 2021, all 2020 and 2021 model year subject buses at the first customer received a software update to open and de-energize the ultracapacitor contactors when the battery disconnect switch is in the off position.  Subsequently the 2014-2019 buses were also updated.

 

In April 2022, Gillig received a communication from NHTSA advising that the first customer had submitted a complaint to the agency about the performance of the ultracapacitor system and alleging that the buses could be started even though the battery disconnect switch was in the “disconnected” position and claimed that this condition created a safety concern.  Gillig reviewed this communication and the customer’s allegation and the following day the customer confirmed to Gillig that all of its affected buses had already received the software update prior to submitting its report to NHTSA.   Gillig continued to review and consider the design of the ultracapacitor on the subject buses, particularly in light of the redundant series of instructions and practices that personnel are supposed to take in order to prevent the bus engine from being started during maintenance.

 

On April 22, 2022, notwithstanding the other redundant precautions, each of which entirely preclude the safety risk addressed in this petition, Gillig decided to conduct a safety recall out of an abundance of caution.  Gillig is not aware of any injuries that are potentially related to the condition.

 


8 Affected Products

Vehicle

MAKE MODEL YEAR
GILLIG LOW FLOOR 2014-2021

 


8 Associated Documents

Miscellaneous Document- Chronology

RMISC-22V276-4320.pdf 98.106KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [95.81 KB]

 


Defect Notice 573 Report

RCLRPT-22V276-1710.PDF 215.824KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [210.77 KB]

 


Recall Acknowledgement

RCAK-22V276-4651.pdf 647.171KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [632.00 KB]

 


Recall 573 Report- 06/08/2022

RCLRPT-22V276-5002.PDF 216.015KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [210.95 KB]

 


Recall Quarterly Report #1, 2022-2

RCLQRT-22V276-8847.PDF 211.127KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.18 KB]

 


Recall Quarterly Report #2, 2022-3

RCLQRT-22V276-8276.PDF 211.229KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.28 KB]

 


Recall Quarterly Report #3, 2022-4

RCLQRT-22V276-1975.PDF 211.312KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [206.36 KB]

 


Owner Notification Letter(Part 577)

RCONL-22V276-9341.pdf 94.714KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [92.49 KB]

 


Latest Recalls Documents

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

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V276&docType=RCL

 


 

“This site contains affiliate links for which OEMDTC may be compensated”
SaleBestseller No. 1
B Stock IOXUS 12V Group 31 Smart Power Bluetooth Ultra Capacitor
  • Ioxus UltraCapacitor is a Smart Power ultracapacitor-based product for vehicles that improves starting reliability, improves vehicle voltage health, improves battery life, and improves sustainability.
  • With a 15-year design life, you will never change your ultracapacitor again.
  • Bluetooth capability allows for easier control. uStart (App required to utilize Bluetooth capabilities) Bluetooth remote control Application
  • Reducing lead-acid battery count in most cases, and reducing maintenance costs associated with low voltage conditions, the ultracapacitor will ensure that your vehicle is ready to start, always
  • The Ioxus UltraCapacitor will turn on automatically when it sees alternator voltage for the first time
SaleBestseller No. 2
Schumacher DSR108 DSR ProSeries Batteryless Jump Starter - 12V, 450A for Gas and Diesel Engines
  • CHARGE TO JUMP START: Professional grade; use your vehicle outlet to charge the jump starter in just two minutes, preparing it for future use
  • RELIABLE POWER: Provides a 450-amp jump start for gas and diesel engines
  • MANY WAYS TO USE: Connect clamps to vehicle battery, vehicle’s 12-volt DC port, or a power bank via micro USB port (cable not included)
  • SAFE AND LONG-LASTING: Includes short-circuit and reverse polarity protection; up to 10 times the service life of traditional jump starters
  • COLD START: Glow mode allows for cold start on diesel engines
Bestseller No. 3
6pcs/Set 16V 83F Super Farad Capacitor Single Row with for Board 2.7V 500F Flat Electrolytic High Frequency Low Resistance Ultracapacitor
  • 6pcs/Set 16V 83F Super Farad Capacitor - Single Row with Board, 2.7V 500F Flat Electrolytic High Frequency Low Resistance Ultracapacitor
  • Electrolytic & High Frequency: As a flat electrolytic capacitor, it boasts impressive high-frequency handling capability. Ideal for applications that require quick and reliable power support.
  • Low Resistance: Featuring low internal resistance, our Ultracapacitor is engineered to minimize power loss. Its optimized design results in increased energy efficiency and performance.
  • Board Integration: The Single Row Capacitor is designed with an integrated board, making it easier and more convenient to install. This design makes it flexible for various applications.
  • 6pcs/Set: The set contains 6 high-quality capacitors, making it a cost-effective solution for professionals and hobbyists alike, particularly those working on large-scale or complex projects.
Bestseller No. 4
6PCS Super Capacitor 2.7V 500F 60 35mm Suitable for Automotive Rectifiers Super Farad Condenser
  • Model: 2.7V 500F
  • Size: 35 x 60 (mm)
  • Color: Blue
  • Effect: more than 30 percent away, on the slopes and powerful, but also for solar energy
Bestseller No. 5
I0XUS Professional Super Capacitor 2.7V 3000F Super Farad Condenser LowESR Ultracapacitor for Car Start Rectifiers,Super Farad Capacitor Electrolytic Capacitor Ultracapacitor for Auto
  • It can also be used as a backup power supply for electronic devices, such as intelligent three-waymeters, motor drives, clock circuits, CMOS power outage protections, and otherfields.
  • Wider practicality, suitable for car starting, solar wind, etc. Only supercapacitors
  • Super capacitor only, other accessories demo in the picture is not included!
  • Made of food grade materials, sturdy and durable, pollution-free, with good performances and long service life.
  • Low ESRcharacteristic, fast charging only takes a few seconds.
Bestseller No. 6
Maxwell Durablue 16V 1000F Super Capacitor Battery ultracapacitor Solar Power System Home Audio Power Amplifier Hybrid car Battery
  • Maxwell super capacitor 16V 1000F
  • High Power density: up 6700w/kg
  • Low ESR: can be used as a rechargeable battery and ideal for back up purposes
  • Quick charge: charging 10 seconds to 10 minutes to reach its rated capacity of more than 95%
  • long life: up to 8 million to 120 million cycles
Bestseller No. 7
SaiDian 1 Pcs 16V1F/2F 16V 1.6F Farad Capacitor Module 2.7V 10F Super Capacitors,with Protection Board
  • Model:16V1.6F;Capacity:1.6F;Voltage:15V-16V.
  • Large current discharge,safe and easy to use.
  • Internal series structure, low internal resistance, high energy
  • As CMOS,RAM,VCR,radio,TV,telephone,intelligent instrumentation,driving record,IC three tables electronic watches,LED flashlight,LED lighting, smart appliances,toys,motor,DC,industrial UPS,electromagnetic Valves,voice IC,LED light and other ideal backup power supply.
  • Size:6.5x3.0x1.3cm/2.55x1.18x0.51inch(LengthxHeightxThickness)
Bestseller No. 8
1Set(6pcs) 2.7V 500F 35x60MM Farad Capacitor Super Capacitor with Protection Board
  • 2.7V 500F 35X60mm
  • Total Size: about 23x3.5x6cm;Single capacitor diameter: 3.3cm
  • You can use ordinary battery chargers with a voltage of 10-13V and a current of 10-40A
  • Protect the original car battery and electrical circuit system, reduce its load
  • Enhance the engine power, make the accelerator response lighter and more sensitive
Bestseller No. 9
Cermant 10 pcs 8X12mm(0.31x0.47in) Super Capacitor 2.7V 1F Farad Capacitance Winding Type Energy Storage for On Board Backup Energy Storage
  • Farad capacitance 2.7V/1F,Winding Type,Monomer,High capacity,High power
  • High energy and high current,Flame retardant, insulation, good frequency characteristics ,Strong overload capacity, stable performance,High impact current resistance and reliability
  • Low leakage and long service life,High temperature resistance, low temperature rise and high adhesion,Low loss, low leakage, safety, good self-healing performance and reliable use
  • Typical applications: ram, detonator, automobile recorder, intelligent instrument, vacuum switch, digital camera, Mada drive,Motor, clock circuit, UPS, toys, SPC exchange, etc
  • Package:10pcs 2.7V 1F Farad Capacitance
Bestseller No. 10
Maxwell 48v 165F Super Capacitor 2.7v 3000F ultracapacitor for Solar Energy Storage,UPS Supply,Power Tools, Motor Starting
  • 【Powerful Performance:】 48V 165F (18pcs * 2.7v 300F) Supercapacitor, featuring reliable and efficient energy storage, with a built-in voltage protection board, suitable for various applications.
  • 【Sturdy Design:】 Weighing 28.66 lbs (13kg) and measuring 20.47 inches x 9.45 inches x 8.66 inches (US standard), designed for durability and easy installation.
  • 【Temperature Adaptability:】 Performs exceptionally well in temperatures ranging from -45°F to 158°F, ensuring consistent energy output in extreme weather conditions.
  • 【Long Cycle Life:】 With a cycle life exceeding 1,000,000 cycles, ensuring a prolonged and stable power supply.
  • 【Versatile Applications:】 Suitable for various fields, including industrial automation, electric vehicles, communication equipment, providing reliable energy support for diverse applications.

Last update on 2024-03-14 / Affiliate links / Images from Amazon Product Advertising API

This product presentation was made with AAWP plugin.

 


Leave a Comment

Share to...