Undersized Wire in Power Control System – 2024 Brinkley RV Model G Fifth Wheel Toy Haulers

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-664 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Brinkley RV Submission Date : SEP 29, 2023 NHTSA Recall No. : 23V-664 Manufacturer Recall No. : PCI-2023-01 Manufacturer Information : Manufacturer Name : Brinkley RV Address : 1655 Brinkley Way East GOSHEN IN 46528 Company phone : 574-501-4280 Population : Number of potentially involved : 143 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2024-2024 Brinkley RV G Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : Power Train : NR Descriptive Information : The recall population was determined by starting with the first 2024 Brinkley RV Model G VIN produced. When the at issue defect was discovered, Brinkley instituted a stop ship at its facility to permit the defective component to be replaced with the compliant version. The VIN range is exclusive of any units that were fixed before the unit left Brinkley’s premises. The at issue component is the Power Control System manufactured by Precision Circuits. The recalled product differs from products not included in this recall in that the recalled version contains 88 inches of 10 gauge wiring and the compliant version contains 88 inches of 6 gauge wiring for the neutral wire utilized by the Power Control System. The number of affected products related to this specific make/model/model year combination is 143. Production Dates : FEB 06, 2023 – SEP 06, 2023 VIN Range 1 : Begin : 7T0FG4238RT000004 End : 7T0FG4238RT000004 Not sequential VIN Range 2 : Begin : 7T0FG4237R1000006 End : 7T0FG4239R1000010 Not sequential VIN Range 3 : Begin : 7T0FG4232R1000012 End : 7T0FG4237R1000121 Not sequential VIN Range 4 : Begin : 7T0FG4230R1000123 End : 7T0FG4231R1000129 Not sequential VIN Range 5 : Begin : 7T0FG4231R1000132 End : 7T0FG4231R1000132 Not sequential VIN Range 6 : Begin : 7T0FG4235R1000134 End : 7T0FG4239R1000136 Not sequential VIN Range 7 : Begin : 7T0FG4232R1000138 End : 7T0FG4238R1000144 Not sequential VIN Range 8 : Begin : 7T0FG4231R1000146 End : 7T0FG4236RB000153 Not sequential VIN Range 9 : Begin : 7T0FG4730RB000156 End : 7T0FG4730RB000156 Not sequential Part 573 Safety Recall Report 23V-664 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Precision Circuits utilized/installed the incorrect wire gauge in its Power Control System for the 50 amp service application required by Brinkley Model G. Precision Circuits production inadvertently utilized 88 inches in length of 10 gauge wiring in lieu of 88 inches in length of 6 gauge wiring for the neutral wire utilized by the Power Control System. The incorrect wire gauge was immediately corrected in production by Precision Circuits upon discovery. Brinkley RV also instituted a stop ship of its units still located at Brinkley RV to permit the correct version of the Power Control System to be installed to further limit the subject VIN range. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Brinkley RV and Precision Circuits believe that the risk to safety due to thermal event is extremely improbable. However, utilization of 10 gauge wiring in lieu of 6 gauge for 50 Amp applications is in violation of applicable code. When all electrical equipment is utilized simultaneously in the Brinkley RV Model G recreational vehicles, the max amperage on the Power Control System could exceed the maximum NEC rating of the 10 gauge wiring inadvertently utilized. After conducting laboratory testing instructed by the max amperage output of a Brinkley Model G (37 Amps), the wiring is actually sized correctly for the application. However, the overall RV electrical system is rated at 50 Amps. In order to comply with all codes applicable to the specified 50 Amp system, the wiring should be changed to 6 gauge. The retail owners of the subject units could add equipment to the unit that increases the total amperage exceeding amperage limits of the 10 gauge wiring, potentially resulting in a fire. Description of the Cause : The cause of the non-compliance is human error in the production process of the Power Control System at Precision Circuits. Identification of Any Warning that can Occur : We do not expect any Brinkley RV Model G to encounter an issue given that its maximum amperage output is 37 Amps. That said, should the amperage in the system exceed the 40 Amp rating of the 10 gaugue wiring, the 50 Amp inline circuit protection would trip. Involved Components : Component Name 1 : Power Control System Component Description : Power Control System for 50 Amp Service Component Part Number : 00-10024-900 Part 573 Safety Recall Report 23V-664 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Supplier Identification : Component Manufacturer Name : Precision Circuits, Inc. Address : 2538 Wisconsin Avenue Downers Grove Illinois 60515 Country : United States Chronology : On Thursday, September 21, 2023, during an electrical audit performed at Brinkley RV, it was discovered that the neutral wire for the Power Control System was undersized for a 50 Amp service system. The neutral wire was discovered to be 10 gauge during the audit. Of note is there have been zero reported issues in the field relative to this issue. Precision Circuits was contacted immediately and advised of the error. Thereafter, Precision Circuits traveled to Brinkley RV on September 22, 2023 to review the application and to confirm that the wire in fact was undersized. Immediate corrective action was taken at the Precision Circuits production facility to ensure no other components were built with the undersized wiring. All Brinkley RV Model G units located on Brinkley RV premises were subjected to a stop ship to permit all units to be remedied prior to shipment. Precision Circuits manufactured new Power Control System assemblies and helped to facilitate swapping the correct systems for those units containing undersized wiring version of the Power Control System. Once completed, Brinkley RV permitted those units to ship as the intended remedy was supplied in those units and effectively removed them from the VIN range of this recall. In parallel, Precision Circuits also performed lab testing to evaluate the risk related to amperage draw and temperature and found that the wire was at no risk of component failure or fire hazard when continuously subjected to 50Amps of power. Despite this determination by Precision Circuits, Brinkley RV and Precision Circuits both still agreed that changing to the 6 gauge neutral wire is necessary and should be performed to be in compliance with applicable code. Owners of Brinkley Model G units may elect to add additional power equipment to the RV in reliance on the 50 Amp rating of the RV. The recall is being instituted to ensure there is no possibility of a thermal event occurring. Description of Remedy : Description of Remedy Program : Precision Circuits will supply to Brinkley RV pre-packaged boxes containing the new code-compliant Power Control Systems and including the replacement instructions therein. Brinkley RV will be notifying all of its affected dealers and retail customers and will ship out the replacement parts upon request. Brinkley RV will indicate to both dealers and customers that the remedy will be supplied free of charge and all reimbursements for any out of pocket expenses by a dealer or retail customer can be submitted to Brinkley RV for immediate reimbursement. How Remedy Component Differs The neutral wire on the remedy component is 6 gauge THHN or THHW Part 573 Safety Recall Report 23V-664 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 from Recalled Component : 600V wire. The neutral wire on the recalled component is 10 gauge THHW 600V wire. Identify How/When Recall Condition was Corrected in Production : On September 22, 2023, when Precision Circuits verified the undersized wiring condition, it immediately halted production and ensured that all components built thereafter utilize the 88 inches of 6 gauge THHN wire. A stop ship was instituted and any Power Control System that was built prior thereto was quarantined and the neutral wire sizing remedied. Brinkley RV also instituted a stop shipment on its Model G units until the remedy component (Power Control System) was installed on all units still within Brinkley RV’s possession. Further, any stock in the possession of Brinkley RV was swapped out for compliant Power Control Systems. Any in process production units containing the non-compliant Power Control Systems were remedied prior to them coming off the production line. Recall Schedule : Description of Recall Schedule : Brinkley RV will notify all dealers how either have or had inventory of 2024 Brinkley Model G units within the subject range, advising of the recall and remedy. Thereafter, Brinkley RV will noitify all registered retail customers of the same. Planned Dealer Notification Date : OCT 09, 2023 – OCT 09, 2023 Planned Owner Notification Date : OCT 16, 2023 – OCT 16, 2023 * NR – Not Reported

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WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 1 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours PURPOSE This document refers to Brinkley Model G Series 5th Wheels and the requirement to replace the 10-gauge white wire with a larger 6-gauge white wire in the energy management Power Control System. This will be done by replacing the complete box assembly that houses the wiring. NOTE: IT IS IMPORTANT THAT ALL NEW PARTS ARE ORDERED USING KIT PN 00-10024T950. UTILIZE ALL NEW PARTS. DO NOT REUSE THE OLD PARTS, EVEN IF THE OLD PARTS DO NOT APPEAR TO BE COMPROMISED. It is suspected that when all electrical equipment is utilized simultaneously in the Brinkley RV Model G recreational vehicles, the max amperage on the Power Control System could exceed the maximum NEC rating of the 10-gauge wiring currently used in the assembly. After conducting laboratory testing instructed by the max amperage output of a Brinkley Model G (37 Amps), the wiring is sized correctly for the application. However, since the overall RV electrical system is rated at 50 Amps and to comply with the specified 50 Amp system, the wiring should be changed to 6 gauge to ensure code compliance. As a result, Precision Circuits has elected to replace the Power Control System assembly which includes the wiring in question on the Brinkley Model G 5th Wheel units. This will affect dealer inventory as well as retail owned vehicles. See the specific affected VIN’s in the table below. Below you will find work instructions, parts ordering information and details to file a Pre-Authorization to claim for reimbursement. Within the next couple of days, Brinkley representatives may call your dealership to help facilitate parts ordering. Communication will be provided to retail customers, and we ask that you provide priority scheduling to perform the Recall. Precision Circuits and Brinkley have technical service teams available to help you, should you need it. LASTLY AS PART OF THE INVESTIGATION, WE ASK THAT YOU RETURN YOUR OLD POWER CONTROL SYSTEM ASSEMBLY BACK TO PRECISION CIRCUITS USING THE INCLUDED UPS RETURN LABEL IN THE KIT. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 2 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours PART TO ORDER: PN 00-10024T950 VIN Information DESCRIPTION: BRINKLEY MODEL G PCI-2023-01 Recall Units with VIN ending in 000157 and Higher are not affected by this Recall. Please submit all orders with the Brinkley VIN via the Brinkley Portal. Any questions can be directed to [email protected]. One Assembly (PN 00-10024T950) is required to perform the Recall. PRIOR AUTHORIZATION REQUIRED THROUGH BRINKLEY RV. BRV Flat Rate Code: 900001 CLAIM REIMBURSEMENT PROCESSING: All completed work orders with requests for reimbursement, including any freight expenses, should be submitted to Brinkley via the Brinkley Portal. Any questions can be directed to [email protected]. REQUIRED INFORMATION FOR IMMEDIATE REIMBURSEMENT PROCESSING INCLUDES: Full 17-digit VIN, Retail Name if retail sold, Dealer Name, address, phone number, dealer hourly labor rate and a work order detailing the work performed and labor time. Additionally, the recalled Power Control System must be returned to Precision Circuits utilizing the provided return label. Claims submitted with all requested information are issued payment within 30 days. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 3 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours Return Shipping Address: Parts being replaced are to be returned to: Precision Circuits Inc. 2538 Wisconsin Ave. Downers Grove, IL 60515 Attn: Brinkley Recall SAFETY This document provides general instructions. Many variables can change the circumstances of any procedure, i.e. the degree of difficulty involved in the service operation and the ability level of the individual performing the operation. This document cannot begin to plot out procedures for every possibility, but will provide the general instructions for effectively installing, removing or servicing the system. In the event the skill level required is too advanced or the procedure too difficult, a certified technician should be consulted before performing the necessary operation. Failure to correctly install, remove or service the system may result in voiding warranty, inflicting injury or even cause death. The ”WARNING” symbol above is a sign that a procedure has a safety risk involved and may cause death, serious personal injury, severe product and/or property damage if not performed safely and within the parameters set forth in this document. The “CAUTION” symbol above is a sign that a procedure has a safety risk involved and may cause personal injury, product and/or property damage if not performed safely and within the parameters set forth in this document. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 4 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours RESOURCES REQUIRED • Recall Replacement Power System Control Assembly – PN 00-10024T950 • Cordless Electric drill or screw gun • Appropriate drive bits • Appropriate Screw Drivers • Wire strippers • Torque driver NOTE: IT IS IMPORTANT THAT ALL NEW PARTS ARE ORDERED USING KIT PN 00-10024T950. UTILIZE ALL NEW PARTS. DO NOT REUSE THE OLD PARTS, EVEN IF THE OLD PARTS DO NOT APPEAR TO BE COMPROMISED. NOTE: ALL WORK MUST BE PERFORMED BY A CERTIFIED ELECTRICIAN, ELECTRICAL TECNICIAN, OR RV TECHNICIAN TO RECEIVE REIMBURSEMENT AND TO MAINTAIN THE PROVIDED RV WARRANTIES. Removal of Old Power Control System (PCS) Assembly THE REPLACEMENT OF THE POWER CONTROL SYSTEM SHOULD ONLY BE PERFORMED BY A LICENSED ELECTRICIAN, AN ELECTRICAL TECHNICIAN OR AN RV TECHNICIAN. THE WORK TO BE PERFORMED CARRIES THE RISK OF ELECTRIC SHOCK. DISCONNECT INCOMING POWER BEFORE PERFORMING THE WORK OUTLINED BELOW. UNPLUG THE UNIT FROM SHORE POWER AND ENSURE THE BATTERY DISCONNECTS ARE IN THE OFF POSITION. ALWAYS TEST WIRING FOR POWER PRIOR TO TOUCHING OR ATTEMPTING TO CONNECT OR DISCONNECT ANY WIRING. FAILURE TO HEED THESE WARNINGS COULD RESULT IN ELECTRICAL SHOCK, SERIOUS INJURY, OR EVEN DEATH. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 5 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 1. Locate the Power Distribution Panel behind the Kitchen Cabinet. 2. Open the door of the Power Distribution Panel and loosen the screws (2) on the door and slide the cover panel to the left to remove the front cover. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 6 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 3. Remove the 12-gauge black wire and red wire from Wago Connectors for wires connecting to the Power Control System. A close up of the top circle in the above photo. A close up of the middle circle in the above photo. This is where the Power Contol System wires enter into the panel from back of the power distribution center. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 7 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 4. Loosen the screws for the neutral wires going to Power Control System (2) and pull the wires out of buss bar. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 8 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 5. Loosen the screws for the other neutral wires that are in front of blue wire nut and pull the wires out of the buss bar. Move the removed neutral wires out of the way to gain access and remove the blue wire nut. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 9 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 6. Loosen and remove the blue wire nut and tape and pull the white #10 wire out towards the inlet of the Power Control System wiring. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 10 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 7. With the wire nut and wires out of the way, loosen the screw holding the green wire from the Power Control System and remove and pull the green wire over towards the Power Control System inlet. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 11 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 8. After all wires going to the Power Control System are now loose, remove the screws (4) from the Power Distribution Panel and remove it from the cabinet. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 12 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 9. Locate the electrical box located inside the cabinet and loosen the screws (2) on top of electrical box. Then, slide the cover to remove. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 13 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 10. Once the electrical box cover is off, remove screws (2) located in the bottom of the box that hold the box to the floor. These two screws are located in the same corner areas as the screws that held the cover on. (This may take a longer or flex attachment to reach the screws). WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 14 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 11. Then remove the screw (1) and conduit clamp holding the flexible conduit to the floor. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 15 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 12. Loosen the nut on the back of the Power Center Panel and pull out the flex conduit and wiring out of the Power Center Panel. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 16 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 13. Remove the original Flexible Conduit Connector from the back of the Electrical Panel. 14. Completely Remove the original Power Control System Electrical Box and Flex Conduit. THIS IS THE ASSEMBLY THAT MUST BE RETURNED TO PRECISION CIRCUITS. DO NOT DISCARD. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 17 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours Installing the New Power Control System Assembly (Reverse order of Removal) 1. Prep the new replacement Power Control System Box and Conduit by removing the nut and rubber washer from the flexible conduit box connector. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 18 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 2. Insert the new Power Control System Flexible Conduit Box Connector and Wiring into the back of the Electrical Panel where the old system was removed. Connect and tighten the flexible box connector nut. 3. Route the ground and neutral wires back to where the old wiring was located (behind the neutral wires). This is where the old wiring was pulled out from. Install Box Connector Nut Entry Point WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 19 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 4. Attach the ground wire back to buss bar where old ground was located. Torque to 25 in-lbs (2.8 Nm). 5. Cut and strip one of the new 6-gauge white wires to length to match the current 6-gauge wire in the Electrical Panel and tape together. Use blue wire nut (twist to tighten) to connect the two 6-gauge wires and tape over the wires and nut. Push the wires and nut back into the Electrical Panel. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 20 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 6. Cut and strip the 2nd 6-gauge white wire from the new Power Control System assembly and attach to neutral buss bar where previous 10-gauge wire was from the old system. Torque to 35 in-lbs (4.0 Nm). 7. Attach small 18-gauge neutral from the new Power Control System assembly wiring to the neutral buss bar where old system 18 gauge was attached. Torque to 25 in.-lbs (2.8 Nm). WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 21 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 8. Reattach all the neutral wires that were previously pulled out of buss bar in order to access and the blue wire nut. Torque to 25 in.-lbs (2.8 Nm). WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 22 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 9. Reattach 12-gauge black wire and red wire to Wago Connectors the for wires going to Power Control System. WIRE CHANGE FOR 50AMP POWER CONTROL SYSTEM ON BRINKLEY MODEL G 5TH WHEELS 23 Recall Number: Brinkley RV ID: PCI-2023-01; NHTSA Recall No. 23V-664 Product: Power Control System Date: September 28,2023 Labor Rate: 1.0 hours 10. Place the new Power Control System electrical box back into the cabinet space where the old system was located and fasten the box to the floor using the flexible conduit clamp supplied in the replacement kit. Mount this clamp as close to the electrical box as possible. 11. Reinstall the Electrical Panel into the cabinet opening using screws (4) previously removed and reattach the front cover using the 2 screws for the cover. 12. The installation is now complete.

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-664 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Brinkley RV Submission Date : OCT 17, 2023 NHTSA Recall No. : 23V-664 Manufacturer Recall No. : PCI-2023-01 Manufacturer Information : Manufacturer Name : Brinkley RV Address : 1655 Brinkley Way East GOSHEN IN 46528 Company phone : 574-501-4280 Population : Number of potentially involved : 143 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2024-2024 Brinkley RV G Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : Power Train : NR Descriptive Information : The recall population was determined by starting with the first 2024 Brinkley RV Model G VIN produced. When the at issue defect was discovered, Brinkley instituted a stop ship at its facility to permit the defective component to be replaced with the compliant version. The VIN range is exclusive of any units that were fixed before the unit left Brinkley’s premises. The at issue component is the Power Control System manufactured by Precision Circuits. The recalled product differs from products not included in this recall in that the recalled version contains 88 inches of 10 gauge wiring and the compliant version contains 88 inches of 6 gauge wiring for the neutral wire utilized by the Power Control System. The number of affected products related to this specific make/model/model year combination is 143. Production Dates : FEB 06, 2023 – SEP 06, 2023 VIN Range 1 : Begin : 7T0FG4238RT000004 End : 7T0FG4238RT000004 Not sequential VIN Range 2 : Begin : 7T0FG4237R1000006 End : 7T0FG4239R1000010 Not sequential VIN Range 3 : Begin : 7T0FG4232R1000012 End : 7T0FG4237R1000121 Not sequential VIN Range 4 : Begin : 7T0FG4230R1000123 End : 7T0FG4231R1000129 Not sequential VIN Range 5 : Begin : 7T0FG4231R1000132 End : 7T0FG4231R1000132 Not sequential VIN Range 6 : Begin : 7T0FG4235R1000134 End : 7T0FG4239R1000136 Not sequential VIN Range 7 : Begin : 7T0FG4232R1000138 End : 7T0FG4238R1000144 Not sequential VIN Range 8 : Begin : 7T0FG4231R1000146 End : 7T0FG4236RB000153 Not sequential VIN Range 9 : Begin : 7T0FG4730RB000156 End : 7T0FG4730RB000156 Not sequential Part 573 Safety Recall Report 23V-664 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Precision Circuits utilized/installed the incorrect wire gauge in its Power Control System for the 50 amp service application required by Brinkley Model G. Precision Circuits production inadvertently utilized 88 inches in length of 10 gauge wiring in lieu of 88 inches in length of 6 gauge wiring for the neutral wire utilized by the Power Control System. The incorrect wire gauge was immediately corrected in production by Precision Circuits upon discovery. Brinkley RV also instituted a stop ship of its units still located at Brinkley RV to permit the correct version of the Power Control System to be installed to further limit the subject VIN range. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Brinkley RV and Precision Circuits believe that the risk to safety due to thermal event is extremely improbable. However, utilization of 10 gauge wiring in lieu of 6 gauge for 50 Amp applications is in violation of applicable code. When all electrical equipment is utilized simultaneously in the Brinkley RV Model G recreational vehicles, the max amperage on the Power Control System could exceed the maximum NEC rating of the 10 gauge wiring inadvertently utilized. After conducting laboratory testing instructed by the max amperage output of a Brinkley Model G (37 Amps), the wiring is actually sized correctly for the application. However, the overall RV electrical system is rated at 50 Amps. In order to comply with all codes applicable to the specified 50 Amp system, the wiring should be changed to 6 gauge. The retail owners of the subject units could add equipment to the unit that increases the total amperage exceeding amperage limits of the 10 gauge wiring, potentially resulting in a fire. Description of the Cause : The cause of the non-compliance is human error in the production process of the Power Control System at Precision Circuits. Identification of Any Warning that can Occur : We do not expect any Brinkley RV Model G to encounter an issue given that its maximum amperage output is 37 Amps. That said, should the amperage in the system exceed the 40 Amp rating of the 10 gaugue wiring, the 50 Amp inline circuit protection would trip. Involved Components : Component Name 1 : Power Control System Component Description : Power Control System for 50 Amp Service Component Part Number : 00-10024-900 Part 573 Safety Recall Report 23V-664 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Supplier Identification : Component Manufacturer Name : Precision Circuits, Inc. Address : 2538 Wisconsin Avenue Downers Grove Illinois 60515 Country : United States Chronology : On Thursday, September 21, 2023, during an electrical audit performed at Brinkley RV, it was discovered that the neutral wire for the Power Control System was undersized for a 50 Amp service system. The neutral wire was discovered to be 10 gauge during the audit. Of note is there have been zero reported issues in the field relative to this issue. Precision Circuits was contacted immediately and advised of the error. Thereafter, Precision Circuits traveled to Brinkley RV on September 22, 2023 to review the application and to confirm that the wire in fact was undersized. Immediate corrective action was taken at the Precision Circuits production facility to ensure no other components were built with the undersized wiring. All Brinkley RV Model G units located on Brinkley RV premises were subjected to a stop ship to permit all units to be remedied prior to shipment. Precision Circuits manufactured new Power Control System assemblies and helped to facilitate swapping the correct systems for those units containing undersized wiring version of the Power Control System. Once completed, Brinkley RV permitted those units to ship as the intended remedy was supplied in those units and effectively removed them from the VIN range of this recall. In parallel, Precision Circuits also performed lab testing to evaluate the risk related to amperage draw and temperature and found that the wire was at no risk of component failure or fire hazard when continuously subjected to 50Amps of power. Despite this determination by Precision Circuits, Brinkley RV and Precision Circuits both still agreed that changing to the 6 gauge neutral wire is necessary and should be performed to be in compliance with applicable code. Owners of Brinkley Model G units may elect to add additional power equipment to the RV in reliance on the 50 Amp rating of the RV. The recall is being instituted to ensure there is no possibility of a thermal event occurring. Description of Remedy : Description of Remedy Program : Precision Circuits will supply to Brinkley RV pre-packaged boxes containing the new code-compliant Power Control Systems and including the replacement instructions therein. Brinkley RV will be notifying all of its affected dealers and retail customers and will ship out the replacement parts upon request. Brinkley RV will indicate to both dealers and customers that the remedy will be supplied free of charge and all reimbursements for any out of pocket expenses by a dealer or retail customer can be submitted to Brinkley RV for immediate reimbursement. How Remedy Component Differs The neutral wire on the remedy component is 6 gauge THHN or THHW Part 573 Safety Recall Report 23V-664 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 from Recalled Component : 600V wire. The neutral wire on the recalled component is 10 gauge THHW 600V wire. Identify How/When Recall Condition was Corrected in Production : On September 22, 2023, when Precision Circuits verified the undersized wiring condition, it immediately halted production and ensured that all components built thereafter utilize the 88 inches of 6 gauge THHN wire. A stop ship was instituted and any Power Control System that was built prior thereto was quarantined and the neutral wire sizing remedied. Brinkley RV also instituted a stop shipment on its Model G units until the remedy component (Power Control System) was installed on all units still within Brinkley RV’s possession. Further, any stock in the possession of Brinkley RV was swapped out for compliant Power Control Systems. Any in process production units containing the non-compliant Power Control Systems were remedied prior to them coming off the production line. Recall Schedule : Description of Recall Schedule : Brinkley RV will notify all dealers how either have or had inventory of 2024 Brinkley Model G units within the subject range, advising of the recall and remedy. Thereafter, Brinkley RV will noitify all registered retail customers of the same. Planned Dealer Notification Date : OCT 16, 2023 – OCT 18, 2023 Planned Owner Notification Date : OCT 23, 2023 – OCT 25, 2023 * NR – Not Reported

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