CR5570 – Improperly Tightened Nut May Cause Electrical Arc – 2021-2022 Nova Bus LFS Artic & 2021-2023 LFS

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-203
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Nova Bus (US) Inc. MAR 17, 2024 NHTSA Recall No. : 24V-203 Manufacturer Recall No. : CR5570 Manufacturer Information :
Manufacturer Name : Nova Bus (US) Inc. Address : 260 Banker Road
PLATTSBURGH NY 12901
Company phone : 450-472-6410
Population :
Number of potentially involved : 688 Estimated percentage with defect : 22 %
Vehicle Information : Vehicle 1 : 2021-2022 Nova LFS Artic
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : The recall population is defined by vehicles built at Nova Bus’ Plattsburg plant using the assembly instructions C113A for the installation of the EMP Alternator prior to January 08, 2024. Nova LFS Artic MY 2021, 2022 33 buses.
Production Dates : JUN 15, 2021 – OCT 26, 2022 VIN Range 1 : Begin : 4RKYS92J3M9777922 End : 4RKYS92J0N9778530 ✔ Not sequential Vehicle 2 : 2021-2023 Nova LFS
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : The recall population is defined by vehicles built at Nova Bus’ Plattsburg plant using the assembly instructions C113A for the installation of the EMP Alternator prior to January 08, 2024. Nova LFS MY 2021-2023 655 buses.
Production Dates : JUN 14, 2021 – JAN 06, 2024 VIN Range 1 : Begin : 4RKYL82J2M9777921 End : 4RKYL82J5P9778985 ✔ Not sequential Description of Defect :
Description of the Defect : The nut for the power cable stud on the alternator may
not have been torqued properly on vehicles in the affected population.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : In the event that the power cable is not torqued properly, arcing may occur. Part 573 Safety Recall Report 24V-203 Page 2 Description of the Safety Risk : Arcing due to a loose cable connection on an unfused power cable may
increase the risk of a fire.
Description of the Cause : The assembly instructions did not clearly identify the required applied torque. Identification of Any Warning
that can Occur : There is no warning prior to occurrence. Involved Components : Component Name 1 : CABLE ASSY Component Description : C1401 4/0 AWG BK-RD Component Part Number : N101828-05 Supplier Identification : Component Manufacturer
Name : Nova Bus
Address : 1000 boulevard Industriel
Saint Eustache Foreign States J7R 5A5 Country : Canada Chronology :
December 28, 2023: Nova Bus was notified that a maintenance technician found evidence of arcing on the power cable to the alternator on a single bus.
January 04, 2024: A preliminary inspection of additional buses was performed.
January 08, 2024: Nova Bus opened an investigation to determine the potential scope and risk level. January 08, 2024: An internal campaign issued to ensure the correct torque was applied to buses under manufacturing control.
January 10, 2024: Product Safety Evaluation Committee evaluates the preliminary information.
January 18, 2024: Product Safety Evaluation Committee raises the investigation to PSRI status and additional field information is gathered.
March 07, 2024: Product Safety Evaluation Committee evaluates the investigation findings and raises to the Product Safety Committee.
March12, 2024: Product Safety Committee makes the determination of a product safety defect.
March 17, 2024: Nova Bus files DIR with NHTSA that a voluntary recall will be released to address the safety- related defect. There have been no accidents or injuries related to this defect. There have been no warranty claims attributed The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-203
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
to this issue. The original vehicle is the only vehicle that showed signs of arcing, however 38 vehicles were found where the alternator power cable was identified as loose during the process of the investigation.
Description of Remedy :
Description of Remedy Program : Remedy program will be to inspect the power cable and torque to the
required specification. All costs associated with this corrective measure will be covered by Nova Bus. Pre-notification remedies will be addressed using the Nova Bus general reimbursement plan on file with NHTSA. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Remedied component will have the proper torque applied. N101828-05: CABLE ASSY C1401 4/0 AWG BK-RD.
An Internal Campaign was launched to ensure all vehicles had the correct torque applied in production January 08, 2024. Recall Schedule :
Description of Recall Schedule : Note: Nova Bus does not have a dealer network and the dates entered for
the planned dealer notification begin/end date are only to avoid NHTSA Recall Portal error while submitting the recall report.
Owner notification will begin on or before May 16, 2024 Planned Dealer Notification Date : MAR 20, 2024 – MAR 20, 2024
Planned Owner Notification Date : MAY 16, 2024 – MAY 16, 2024
* NR – Not Reported

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260 Banker road, Plattsburgh, NY, USA 12901 | Tel: 1 800 350-6682 | Fax: 450 974-3001 | us.novabus.com
NQF705001 version 6
IMPORTANT SAFETY RECALL
THIS NOTICE APPLIES TO YOUR VEHICLE – SEE VIN IN APPENDIX A NHTSA RECALL NO. 24V203
Mr. Customer
Transit Bus Agency
260 Banker road
Plattsburgh, NY, USA 12901
April 10th, 2024
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Nova Bus (US) Inc. has decided that a defect which relates to motor vehicle safety exists in certain Nova Bus models LFS and LFS Artic and Model Years 2021 to 2023 manufactured from June 2021 to January 2024 equipped with the EMP alternator assembly.
Certain affected vehicles may have the nut for the power cable stud on the alternator that may not have been torqued properly. In the event that the power cable is not torqued properly, arcing may occur. Arcing due to a loose cable connection on an unfused power cable may increase the risk of fire.
The service document CR5570E explaining the measures to be taken to remedy the affected vehicles will be published on Nova Bus web site https://us.novabus.com/customer-portal/. The vehicles can be remedied starting from April 10th 2024. The remedy, inspection of the power cable and torque to the required specification, should take approximately 30 minutes to complete. The necessary replacement parts will be available via the Nova Bus Parts distribution network. Nova Bus (US) Inc. will covered the parts and labour costs of the repair according to the warranty claim policies in effect. Federal law requires that you forward a copy of this safety recall notice to the lessee within 10 days. If you no longer own this vehicle, or it has been removed from operation permanently, please inform the undersigned.
You may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of a problem associated with this Safety-Related Defect. Please submit copies of all documentation supporting your claim according to the requirements specified in the “General Plan for Reimbursement of Pre-notification Remedies” provided in this notification in Appendix B.
After contacting your customer support manager, if you are still not able to have the Safety-Related Defect remedied without charge and within reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov .
260 Banker road, Plattsburgh, NY, USA 12901 | Tel: 1 800 350-6682 | Fax: 450 974-3001 | us.novabus.com
NQF705001 version 6
Safety is important to us, and we apologize for any inconvenience this situation may cause. Thank you for your attention to this important matter and we look forward to remedying your vehicle. If you have any questions regarding this Safety-Related Defect notification, please contact your customer support manager.
Sincerely,
Daniel Theriault
Director, Field Service
260 Banker road, Plattsburgh, NY, USA 12901 | Tel: 1 800 350-6682 | Fax: 450 974-3001 | us.novabus.com
NQF705001 version 6
APPENDIX A
Make
Model
Model Year
Road #.
VIN
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
Nova Bus
260 Banker road, Plattsburgh, NY, USA 12901 | Tel: 1 800 350-6682 | Fax: 450 974-3001 | us.novabus.com
NQF705001 version 6
APPENDIX B
General Plan for Reimbursement of Pre-Notification Remedies
When a Nova Bus vehicle is affected by a Safety Recall and the owner/purchaser (claimant) has the Safety-Related Defect or Noncompliance remedied at their own expense prior to receiving the manufacturer notification, Nova Bus (US) Inc. will reimburse the owner/purchaser for the reasonable amount paid (i.e. the cost of parts, labor, disposal fees and taxes) that addressed the Safety-Related Defect Noncompliance as described in the notification. To qualify, repairs must have been completed no earlier than one year prior to the release of the Safety Recall (notification to NHTSA) and no later than 10 days after the last mailing of the owner notification letters.
All claims must be accompanied by accurate and complete documentation (the invoice/receipt must provide the VIN, date of repair, total amount paid and include a breakdown of the parts, labor, and other costs. Specific costs associated with this notification must be highlighted or circled on the invoice).
The following information is required for your claim to be processed. Please print legibly.
Date: _________________ Recall #: ______________ 17 digits VIN: ________________________________
Owner’s Name: ________________________________ Own / Lease (circle one)
Address: ______________________________________ Date of Repair: _______________________________
City, State, Zip: ________________________________ Amount Requested: ___________________________
Phone#: _______________________________________ Email: _______________________________________
I CERTIFY THAT I PAID FOR REPAIRS THAT REMEDIED THE SAFETY-RELATED DEFECT OR NONCOMPLIANCE AS DESCRIBED IN THE OWNER NOTIFICATION LETTER PRIOR TO BEING NOTIFIED. I ALSO CERTIFY THAT I HAVE PROVIDED CLEAR DOCUMENTATION OF THESE REPAIRS AND THAT ALL INFORMATION PROVIDED IS COMPLETE AND ACCURATE TO THE BEST OF MY KNOWLEDGE.
Claimant
__________________________________________________________________ _____________________
Authorized signature and date
Contact Information
Submit your claim together with copies of all supporting documentation to:
Nova Bus Warranty, TMAC
850, chemin Olivier
Saint-Nicolas (QC) G7A 2N1
Canada
Email: adm.novabus.warranty@volvo.com
Allow 60 days for processing and decision. Nova Bus (US) Inc. is not responsible for claims submitted to the wrong address.
This process is not intended to handle incident, accident or property damage claims. Claims of that nature must be directed to our legal department at 1000 Industriel Boulevard, Saint-Eustache, QC, Canada J7R 5A5.

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