Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760A
NHTSA #18V-116

Subject: uSTART Ultra Capacitors
Models Affected: Specific Freightliner Custom Chassis
MT45G/55G chassis manufactured June 22, 2017, through
October 31, 2017, and equipped with uSTART Ultra Capacitors.

General Information
Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Freightliner Custom
Chassis Corporation, has decided that a defect that relates to motor vehicle safety exists on the vehicles
mentioned above.
There are approximately 584 vehicles involved in this campaign.
A bracket used to secure the ultra capacitor to the battery tray may cause damage to the upper surface of the
capacitor and allow water to enter the capacitor. Water entering the capacitor could lead to corrosion, a short,
or possible fire within the battery box.
The capacitor will be replaced with a conventional battery.
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.

Work Instructions
Please refer to the attached work instructions. Prior to performing the campaign, check the vehicle for a
completion sticker (Form WAR260).

Replacement Parts
Replacement parts are now available and can be obtained by ordering the part number listed below from your
facing Parts Distribution Center.
If our records show your dealership has ordered any vehicles involved in campaign number FL760A, a list of
the customers and vehicle identification numbers will be available in OWL. Please refer to this list when
ordering parts for this recall.
Table 1 - Replacement Parts for FL760
Campaign Number

FL760A

Part Description

Part Number

Qty.

BATTERY-ALLIANCE,7T31,730CCA,GRP31

A66-01551-008
or
EPM AE7T31
or
ABP AE7T31

1

Table 1

Removed Parts
U.S. and Canadian Dealers, removed uSTART capacitors will be returned. Please follow the instruction
below. Any changes to parts disposition will be noted in Warranty Failed Parts Tracking shipping instructions.
Export distributors, please destroy removed parts unless otherwise advised.

Page 1

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760A
NHTSA #18V-116
• Shipping address:
Ioxus® Inc.
18 Stadium Circle
Oneota, New York 13820
• Supplier contact for questions:
Luke Yetto
(877) 751-4222
• Single modules must be wrapped and placed in a box in order to prevent damage. Multiple modules can
be place on a pallet, wrapped, and secured for UPS Ground shipment.

Labor Allowance
Table 2 - Labor Allowance
Campaign
Number

Procedure

Time Allowed
(hours)

SRT Code

Corrective Action

FL760A

Replace uSTART with conventional battery

0.3

996-R031A

12-Repair Recall/Campaign

Table 2

IMPORTANT: When the Recall has been completed, locate the base completion label in the appropriate location on the vehicle, and attach the red completion sticker provided in the recall kit (Form WAR260). If the vehicle does not have a base completion label, clean a spot on the appropriate location of the vehicle and first
attach the base completion label (Form WAR259). If a recall kit is not required or there is no completion sticker
in the kit, write the recall number on a blank sticker and attach it to the base completion label.

Claims for Credit
You will be reimbursed for your parts, labor, and handling (landed cost for Export Distributors) by submitting
your claim through the Warranty system within 30 days of completing this campaign. Please reference the
following information in OWL:
• Claim type is Recall Campaign.
• In the FTL Authorization field, enter the campaign number and appropriate condition code (FL760-A).
• In the Primary Failed Part Number field, enter 25-FL760-000.
• In the Parts field, enter the appropriate part number as shown in the Replacement Parts Table. Manually
choose part A66-01551-008, EPM AE7T31, or ABP AE7T31 to enter into the parts field of claim.
Contact the Warranty Campaigns Department via WSC ticket system concerning questions on the
parts table.
• In the Labor field, first enter the appropriate SRT from the Labor Allowance Table. Administrative time will
be included automatically as SRT 939-0010A for 0.3 hours.
• In the Other Charges field, enter the UPS ground rate for return shipping as follows;
- Expense Type: Freight - Return Shipping
- Description: uStart Capacitor
- Amount: UPS Ground rate of shipment
• The VMRS Component Code is 032-001-001 and the Cause Code is A1 - Campaign.

Page 2

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760A
NHTSA #18V-116

• U.S. and Canada -- Reimbursement for Prior Repairs. When a customer asks about reimbursement,
please do the following:
• Accept the documentation of the previous repair.
• Make a brief check of the customer’s paperwork to see if the repair may be eligible for reimbursement. (See the "Copy of Owner Letter" section of this bulletin for reimbursement guidelines.)
• Submit an OWL Recall Pre-Approval Request for a decision.
• Include the approved amount on your claim in the Other Charges section.
• Attach the documentation to the pre-approval request.
• If approved, submit a based on claim for the pre-approval.
• Reimburse the customer the appropriate amount.
IMPORTANT: OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the
campaign has not been previously completed. Also, check for a completion sticker prior to beginning work.
U.S. and Canadian dealers, contact the Warranty Campaigns Department via Web inquiry at
DTNAConnect.com / WSC, or the Customer Assistance Center at (800) 385-4357, after normal business hours,
if you have any questions or need additional information. Export distributors, submit a Web inquiry or contact
your International Service Manager.
U.S. and Canadian Dealers: To return excess kit inventory related to this campaign, U.S. dealers must submit a
Parts Authorization Return (PAR) to the Memphis PDC. Canadian dealers must submit a PAR to their facing
PDC. All kits must be in resalable condition. PAR requests must include the original purchase invoice number.
Export Distributors: Excess inventory is not returnable.
The letter notifying U.S. and Canadian vehicle owners is included for your reference.
Please note that the National Traffic and Motor Vehicle Safety Act, as amended (Title 49, United States Code,
Chapter 301), requires the owner’s vehicle(s) be corrected within a reasonable time after parts are available to
you. The Act states that failure to repair a vehicle within 60 days after tender for repair shall be prima facie
evidence of an unreasonable time. However, circumstances of a particular situation may reduce the 60 day
period. Failure to repair a vehicle within a reasonable time can result in either the obligation to (a) replace the
vehicle with an identical or reasonably equivalent vehicle, without charge, or (b) refund the purchase price in
full, less a reasonable allowance for depreciation. The Act further prohibits dealers from selling a vehicle unless
all outstanding recalls are performed. Any lessor is required to send a copy of the recall notification to the
lessee within 10 days. Any subsequent stage manufacturer is required to forward this notice to its distributors
and retail outlets within five working days.

Page 3

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760A
NHTSA #18V-116

Copy of Notice to Owners
Subject: uSTART Ultra Capacitors
For the Notice to U.S. Customers: This notice is sent to you in accordance with the National Traffic and Motor
Vehicle Safety Act.
Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Freightliner Custom
Chassis Corporation, has decided that a defect that relates to motor vehicle safety exists on specific Freightliner
Custom Chassis MT45G/55G chassis manufactured June 22, 2017, through October 31, 2017, and equipped
with uSTART Ultra Capacitors.
A bracket used to secure the ultra capacitor to the battery tray may cause damage to the upper surface of the
capacitor and allow water to enter the capacitor. Water entering the capacitor could lead to corrosion, a short,
or possible fire within the battery box.
The capacitor will be replaced with a conventional battery.
Please contact an authorized Daimler Trucks North America dealer to arrange to have the Recall performed and
to ensure that parts are available at the dealership. To locate an authorized dealer, search online at
www.Daimler-TrucksNorthAmerica.com. On the menu tab, select “Contact,” scroll down to “Find a Dealer,” and
select the appropriate brand. The Recall will take approximately one half hour and will be performed at no charge
to you.
You may be liable for any progressive damage that results from your failure to complete the Recall within a
reasonable time after receiving notification.
If you do not own the vehicle that corresponds to the identification number(s) which appears on the Recall
Notification, please return the notification to the Warranty Campaigns Department with any information you can
furnish that will assist us in locating the present owner. If you have leased this vehicle, Federal law requires that
you forward this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law
requires that you forward this notice to your distributors and retail outlets within five working days. If you have
paid to have this recall condition corrected prior to this notice, you may be eligible to receive reimbursement.
Please see the reverse side of this notice for details.
For the Notice to U.S. Customers: If you have questions about this Recall, please contact the Warranty
Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail
address [email protected], or the Customer Assistance Center at (800) 385-4357 after
normal business hours. If you are not able to have the defect remedied without charge and within a reasonable
time, you may wish to submit a complaint to the Administrator, National Highway Traffic Safety Administration,
1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at (888) 327-4236
(TTY: 800-424-9153); or to http://www.safercar.gov.
We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle
safety.

WARRANTY CAMPAIGNS DEPARTMENT
Enclosure

Page 4

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760A
NHTSA #18V-116

Reimbursement to Customers for Repairs
Performed Prior to Recall
If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.
Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the
repair would have cost if completed by an authorized Daimler Trucks North America LLC dealer. The following
documentation must be presented to your dealer for consideration for reimbursement.
Please provide original or clear copies of all receipts, invoices, and repair orders that show:
• The name and address of the person who paid for the repair
• The Vehicle Identification Number (VIN) of the vehicle that was repaired
• What problem occurred, what repair was done, when the repair was done
• Who repaired the vehicle
• The total cost of the repair expense that is being claimed
• Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt)
Reimbursement will be made by check from your Daimler Trucks North America LLC dealer.
Please speak with your Daimler Trucks North America LLC authorized dealer concerning this matter.

Page 5

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760
NHTSA #18V-116

Work Instructions
Subject: uSTART Ultra Capacitor
Models Affected: Specific Freightliner Custom Chassis
MT45G/55G chassis manufactured June 22, 2017, through
October 31, 2017, and equipped with uSTART Ultra Capacitors.

General Safety Precautions
WARNING
Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases,
which could cause a battery to explode, causing serious personal injury, including blindness.
When charging the batteries, gas forms in each cell and escapes through the vent holes. In poorly ventilated
areas, the gas lingers around the battery several hours after it has been charged. The gas is explosive around
sparks, flame, or other intense heat; if ignited, it could cause the battery to explode. Follow these precautions
when charging the batteries.
• Wear safety glasses or a face shield when working with batteries. When many batteries are handled,
wear rubber gloves and an apron to protect clothing.
• Make sure that the area is well ventilated.
• Do not install any lead-acid battery in a sealed container or enclosure. Allow hydrogen gas caused by
overcharging to escape. Exploding hydrogen gas can cause blindness or other bodily injury.
• Make sure that the charger cable leads are clean and making good connections. A poor connection could
cause an electrical arc which could ignite the gas mixture and explode the battery.
• Do not break live circuits at the terminals because a spark usually occurs at the point where a live circuit
is broken. Use care when connecting or disconnecting booster leads or cable clamps on chargers.
• Do not smoke near batteries that are being charged or have recently been charged. Keep the batteries
away from open flames or sparks.
• If the battery is frozen, let it reach room temperature and completely thaw before trying to charge it.
Check for leaks and cracks before charging the battery. Replace the battery if leaks or cracks are seen.
• Take care that tools or metal objects do not fall across the battery terminals.

WARNING
Do not install any lead-acid battery in a sealed container or enclosure. Allow hydrogen gas caused by
overcharging to escape. Exploding hydrogen gas can cause blindness or other bodily injury.

CAUTION
If a metal object connects an ungrounded battery terminal to a nearby metal part of the vehicle which is
grounded, it could short out the batteries, causing sparks and possible property damage.

Page 6

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760
NHTSA #18V-116

Battery Electrolyte Safety Precautions
WARNING
Protect skin and eyes from battery electrolyte (acid). Electrolyte is corrosive and could result in serious
personal injury if splashed on your skin or in your eyes.
If electrolyte is splashed on your skin or in your eye, force the eye open, rinse it with cool, clean water for about
five minutes and call a doctor immediately. Do not add eye drops or other medication unless advised by the
doctor.
If electrolyte is swallowed, drink several large glasses of milk or water. Follow with milk of magnesia, a beaten
raw egg, or vegetable oil. Call a doctor immediately.
Use extreme care to avoid spilling or splashing electrolyte. Electrolyte spilled or splashed on your body or
clothing should be neutralized with baking soda or household ammonia, then rinsed with clean water.
Electrolyte can also damage painted or unpainted metal vehicle parts. If electrolyte is spilled or splashed on any
metal surface, neutralize and rinse it with clean water.
To prevent possible skin burns, do not wear watches, rings, or other jewelry while performing maintenance work
on the batteries.

WARNING
Do not apply pressure to the end walls of a plastic-case battery. This could cause electrolyte to squirt
from the vents, possibly resulting in serious injury to skin or eyes.
When handling plastic-case batteries, use a battery carrier. If one is not available, lift these batteries with your
hands placed at opposite corners of the battery.

Page 7

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760
NHTSA #18V-116

uStart Removal
1. Check the base label (Form WAR259) for a completion sticker for FL760 (Form WAR260) indicating this
work has been completed. The base label is usually located on the passenger-side door, about 12 inches
(30 cm) below the door latch. If a completion sticker is present, no work is needed. If a completion sticker is
not present, proceed to the next step.
2. Park the vehicle, apply the parking brake, and shut down the engine. Chock the tires.
3. Turn off all electrical loads.

WARNING
Put the uStart in "Maintenance Mode" before servicing. An arc flash can occur any time the uStart is
connected or disconnected from the battery. Failure to put the uStart in "Maintenance Mode" could result in serious personal injury.
4. Put the uSTART into "Maintenance Mode." With the battery cables connected, hold the uSTART start button
for 10 seconds until the LED lights turns yellow. See Fig. 1.

1.
2.
3.
4.

Start Button
Positive Terminal
Negative Terminal
LED Status Lights
Fig. 1, uStart Ultra Capacitor

NOTE: If the uSTART is not connected to a battery, it will stay in "Maintenance Mode" and the LED will be off.
In "Maintenance Mode" the uStart has no energy at the terminals
5. Remove the battery cables and interconnectors from the uSTART by first removing the positive cable, and
then the ground. For ease of installation, note the locations of the battery positive and negative terminals.

Page 8

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760
NHTSA #18V-116

6. Remove the battery hold-down fasteners and clamp assembly; then remove the uSTART from the battery
box and set aside. See Fig. 2.

4
5

1

2

3
1
6
7
f541376

09/13/96

1.
2.
3.
4.
5.
6.
7.

Interconnector
Negative Terminal
Clamp Assembly
Hold-Down Nut
Hold-Down Washer
Hold-Down Screw
Positive Terminal
Fig. 2, uStart Battery

Battery Installation
CAUTION
Using an under-capacity battery will result in poor performance and premature battery failure, resulting
in starter damage or reduced starter life.
1. Place the battery in the carrier with the terminals in the proper position, as removed. The batteries should
rest level in the carrier.
2. Install the battery clamp assembly, and tighten the hold-down fasteners to 9 to 12 lbf·ft (1224 to 1632
N·cm). See Fig. 2.
3. For corrosion protection, liberally apply pumpable dielectric grease, part number 48–0239–000, to the battery terminal pads.

Page 9

Daimler Trucks
North America LLC

Recall Campaign

April 2018
FL760
NHTSA #18V-116

CAUTION
Do not overtighten the battery clamp assembly. Overtightening could damage the battery.
4. Connect the battery cables and interconnectors to the batteries; first connect the positive cable to the positive terminal. Next, connect the interconnectors, first positive, then negative. Connect the negative cable to
the negative terminal last.

CAUTION
Make sure all battery connections are installed correctly. Reversed polarity may cause serious damage
to the electrical system.
5. Tighten all battery connections to the torque specifications listed on the battery. On Freightliner batteries,
tighten them 10 to 15 lbf·ft (1360 to 2040 N·cm). The correct torque is important for proper electrical system
operation.
6. Start the engine, and check the operation of the charging system. If needed, adjust or repair the charging
system to obtain the correct charging output.

CAUTION
Make sure all battery terminals are covered with protective caps. Failure to cover the battery terminals
could cause accidental shorting across the posts.
7. Cover the battery terminals with protective plastic caps.

uStart Disposal
IMPORTANT: Do not attempt to store the uSTART inside a building or a vehicle. Do not incinerate, crush, or
dispose of the uStart in the trash. Do not recycle with lead-acid batteries. Do not stack.
All modules must be returned to directly to Ioxus at the following address:
Ioxus® Inc.
Attention: Luke Yetto
18 Stadium Circle
Oneota, New York 13820
Single modules must be wrapped and placed in a box in order to prevent damage. Multiple modules can be
placed on a pallet, wrapped, and secured for shipment.
1. Clean a spot on the base label (Form WAR259). Write the campaign number, FL760, on a blank red
completion sticker (Form WAR260) to indicate the work has been completed and attach it to the base label.

Page 10