March 25, 2024 NHTSA CAMPAIGN NUMBER: 24V230000
Brake Harness Connected Incorrectly
Deenergized brakes will not engage, increasing the risk of a crash.
NHTSA Campaign Number: 24V230
Manufacturer Doosan Portable Power
Components SERVICE BRAKES
Potential Number of Units Affected 960
Summary
Doosan Portable Power (Doosan) is recalling certain 2015-2023 Portable Generator Trailers. The electric brake harness was connected to the battery disconnect switch instead of the positive distribution lug of the battery, deenergizing the brakes when the battery disconnect switch is in the off position.
Remedy
Owners will be instructed to immediately stop towing the affected trailers until repairs have been made. Dealers will correct the wiring, free of charge. Owner notification letters were mailed April 3, 2024. Owners may contact Doosan customer service at 1-800-633-5206. Doosan’s number for this recall is 12-23-8. This recall is an expansion of Doosan recall 23V-859.
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.
March 28, 2024
Technical Service Bulletin:
G25WDO-T4F / G40WDO-T4F / G50WDO-T4F / G70WDO-T4F Electric Brake harness connection with Battery Disconnect option
TSB Number: 12-23-8 Rev. A
Class (AA-Safety Mandatory, A-Mandatory, B-Non-mandatory, Product Improvement, Information Only): AA-Safety Mandatory
Models Affected:
G25WDO-T4F (G06, H45, J02)
G40WDO-T4F (G67, H46, H85)
G50WDO-T4F (F90, H35, H86)
G70WDO-T4F (G14, H41, H66, J48)
Affected Serial Number Range:
| Model | Beginning Serial Number | Ending Serial Number |
| G25WDO-T4F
(G06, H45, J02) | 473915UJZG06 | 511935UEAHJ02 |
| G40WDO-T4F
(G67, H46, H85) | 482723UIABG67 | 511675UEAHH85 |
| G50WDO-T4F
(F90, H35, H86) | 473669UIZF90 | 512882UGAHH86 |
| G70WDO-T4F
(G14, H41, H66, J48) | 477986UHAAG14 | 513023UHAHJ48 |
Audience:
Dealers, National Rental Accounts
Issue:
For the units with electrical brake and battery disconnect options installed and listed on this bulletin, it has been identified that the electric brake harness connection may be connected to the positive distribution lug of the battery disconnect switch instead of the positive battery cable terminal. If connected in this manner and the battery disconnect switch is in the off position, the emergency electric brakes will be deenergized.
Solution:
To correct, please see instructions that follow:
- Disconnect positive battery cable from battery using 1/2” wrench. (Fig. 1)
- Remove metal cover around disconnect switch to expose positive distribution connection (Fig. 2)
- Cut any zip ties that secure the electric battery harness. Loosen and remove distribution nut using 9/16” wrench.
- Remove electric brake harness from positive distribution lug.
- Reinstall distribution nut and secure using 9/16” wrench.
- Replace metal cover around disconnect switch.
- Remove nut from positive battery cable battery terminal using 1/2” wrench
- Install electric battery harness ring terminal onto battery terminal bolt and reinstall nut.
- Install positive battery cable terminal on battery positive post and secure nut tightly on battery terminal using 1/2” wrench.
- Verify electric brake solenoids are operating with battery disconnect in the OFF position.
Chronology :
Doosan Bobcat North America, Inc. received a field report on 10/4/2023 of a portable generator with both electric brake and battery disconnect options that had the electric brake harness connected to the positive distribution post of the battery disconnect switch instead of the positive battery cable terminal.
Based on the field report, Doosan Bobcat North America, Inc. initiated an internal investigation and determined a defect with the connection point of the electrical brake harness on units with both electric brakes and battery disconnect options and reported NHTSA Recall 23V859.
Further investigation revealed that the issue with the electric brake harness being connected to the positive distribution post of the battery disconnect switch extends to models G25-G50 built beginning 10/31/2015 and to model G70WDO-T4F built between 12/14/2016 and 8/31/2023.
The investigation has ruled out this issue in air compressor models and on generator models larger than G70WDO-T4F
12-23-8 – Brake Harness Connected Incorrectly – 2019-2023 Doosan Portable Generator Trailers
9 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| DOOSAN PORTABLE POWER | MOBILE GENERATOR | 2015-2023 |
5 Associated Documents
Defect Notice 573 Report
RCLRPT-24V230-9670.PDF 214.199KB
Recall Acknowledgement
RCAK-24V230-1823.pdf 688.359KB
Manufacturer Notices(to Dealers,etc)
Remedy Instructions and TSB
RCRIT-24V230-9078.pdf 250.257KB
ISSUED Owner Notification Letter(Part 577)
RCONL-24V230-2951.pdf 131.416KB
Latest Recalls Documents
For the Latest and Most recent Recall Information Visit the link below…
- PROVIDES A SAFER AND MORE EFFECTIVE CONNECTION to your trailer, because it doesn’t rust, fray or become damaged while towing which keeps you and your trailer safer when towing
- THE COILED CABLE STAYS SAFELY OFF THE GROUND while you’re towing, preventing wear and tear to the cable and providing years of lasting use
- COATED CABLE WIRE ELIMINATES FRAY and protects your fingers from loose, sharp wire
- MEETS OR EXCEEDS ALL DOT REQUIREMENTS
- EASY ATTACHMENT WITH INCLUDED SPRING CLIP
- BRAIDED STEEL CABLE - Our breakaway switch features a high-quality braided steel cable that is resistant to corrosion. The switch is 48” long in total including the 16 AWG wiring.
- 12v DC POWERED - Our breakaway switch has been designed to be powered by 12v DC power provided by the internal battery, making it portable and easy to use in any vehicle.
- IMPROVES ROAD SAFETY WHEN TOWING - This breakaway switch will engage automatically the trailer's electric brakes if the trailer becomes detached from the tow vehicle.
- Connects tow vehicle to trailer breakaway switch
- Actives trailer brakes when cable is released during a disconnect
- 48-inch long cable
- High-temp nylon pull
- Trailer breakaway battery and system sold separately
- Breakaway Switch: Instantly activates your trailer's electric brakes in the event of a trailer disconnection while moving. Long lasting, weather-resistant components. Works on single or multiple axle trailers. Easily bolts or welds to a trailer frame.
- Long lasting, weather-resistant components.
- More Than Just Parts: From snow and ice equipment to toolboxes, hydraulics, towing, truck and trailer hardware to our innovative lighting products-it's amazing what Buyers Products can do for your truck
- We Do Things The Right Way: We design products like we're building them for ourselves, because we are; Our teams are staffed with engineers and experts who know how to make a product exceptional
- Durable and Dependable: Founded in 1946, Buyers Products has become a leader in the truck equipment industry though our commitment to customer care, innovation, and value across our range of products
- PROVIDES A SAFER AND MORE EFFECTIVE CONNECTION to your trailer, because it doesn’t rust, fray or become damaged while towing which keeps you and your trailer safer when towing
- THE COILED CABLE STAYS SAFELY OFF THE GROUND while you’re towing, preventing wear and tear to the cable and providing years of lasting use
- COATED CABLE WIRE ELIMINATES FRAY and protects your fingers from loose, sharp wire
- MEETS OR EXCEEDS ALL DOT REQUIREMENTS
- EASY ATTACHMENT WITH INCLUDED SPRING CLIP
SEOCONTENT-START
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-230
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Doosan Portable Power MAR 25, 2024 NHTSA Recall No. : 24V-230 Manufacturer Recall No. : 12-23-8 Manufacturer Information :
Manufacturer Name : Doosan Portable Power Address : 1293 GLENWAY DRIVE
STATESVILLE NC 28625
Company phone : 8833500
Population :
Number of potentially involved : 960 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2015-2023 Doosan Portable Power Portable Generators Vehicle Type : TRAILERS Body Style : OTHER Power Train : NR
Descriptive Information : Continued investigation from recall 23v-859 identified that the electrical brake harness could be connected to the battery disconnect positive distribution post instead of the positive battery cable terminal. The affected number of units is the field were determined to be 960 units.
Production Dates : OCT 31, 2015 – AUG 31, 2023
VIN Range 1 : Begin : 4FVGDBAA1GU476110 End : 4FVGMBCB9PU513023 Not sequential Description of Defect :
Description of the Defect : Identified generators with electrical brake and battery disconnect options installed may have the electric brake harness connection connected to the positive distribution lug of the battery disconnect switch instead of the positive battery cable terminal.
FMVSS 1 : 105 – Hydraulic and electric brake systems FMVSS 2 : NR
Description of the Safety Risk : If the electric brake harness is connected to the battery disconnect positive
distribution post instead of the positive battery cable terminal, when the battery disconnect is in the off position, the emergency electric brakes will be deenergized. Deenergized brakes will not engage, increasing risk of crash
Description of the Cause : NR
Identification of Any Warning
that can Occur :
No warning Part 573 Safety Recall Report 24V-230 Page 2 Involved Components : Component Name 1 : Switch, Battery Disconnect Component Description : Switch, Battery Disconnect Component Part Number : 46556146 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
Doosan Bobcat North America, Inc. received a field report on 10/4/2023 of a portable generator with both electric brake and battery disconnect options that had the electric brake harness connected to the positive distribution post of the battery disconnect switch instead of the positive battery cable terminal. Based on the field report, Doosan Bobcat North America, Inc. initiated an internal investigation and determined a defect with the connection point of the electrical brake harness on units with both electric brakes and battery disconnect options and reported NHTSA Recall 23V859. Further investigation revealed that the issue with the electric brake harness being connected to the positive distribution post of the battery disconnect switch extends to models G25-G50 built beginning 10/31/2015 and to model G70WDO-T4F built between 12/14/2016 and 8/31/2023. The investigation has ruled out this issue in air compressor models and on generator models larger than G70WDO-T4F Description of Remedy :
Description of Remedy Program : Customer letters, dealer letters, and a Technical Service Bulletin are being
developed to identify and correct the issue. Additionally, warnings will instruct users to immediately stop towing the affected portable generator until the repairs have been made. This solution will be done at no charge to the customer and the dealers will file for reimbursement through the Doosan warranty system. How Remedy Component Differs from Recalled Component : The electric brake harness will connect to the positive battery cable terminal on corrected units instead of the battery disconnect positive distribution post. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-230
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
On 10/5/2023 all production generators with both electric brake and battery disconnect options were inspected and validated that the electrical harness was connected to the positive battery cable terminal and electrical brake solenoid functioned with the battery disconnect switch in the off position. Recall Schedule :
Description of Recall Schedule : Doosan Bobcat North America, Inc. Power will begin sending out the
letters to Dealers notifying them of the Recall and Technical Service Bulletin informing them of affected models and remedy beginning 12/20/2023. Doosan Bobcat North America, Inc. will begin sending out letters to Owners notifying them of the Recall and steps to take for the remedy beginning on 04/01/2024 or sooner.
Planned Dealer Notification Date : APR 01, 2024 – MAY 31, 2024
Planned Owner Notification Date : APR 01, 2024 – JUN 30, 2024
* NR – Not Reported
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1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 1 of 3
March 28, 2024
Technical Service Bulletin:
G25WDO-T4F / G40WDO-T4F / G50WDO-T4F / G70WDO-T4F Electric Brake harness connection with Battery Disconnect option
TSB Number: 12-23-8 Rev. A
Class (AA-Safety Mandatory, A-Mandatory, B-Non-mandatory, Product Improvement, Information Only):
AA-Safety Mandatory
Models Affected:
G25WDO-T4F (G06, H45, J02)
G40WDO-T4F (G67, H46, H85)
G50WDO-T4F (F90, H35, H86)
G70WDO-T4F (G14, H41, H66, J48)
Affected Serial Number Range:
Model
Beginning Serial Number
Ending Serial Number
G25WDO-T4F
(G06, H45, J02)
473915UJZG06
511935UEAHJ02
G40WDO-T4F
(G67, H46, H85)
482723UIABG67
511675UEAHH85
G50WDO-T4F
(F90, H35, H86)
473669UIZF90
512882UGAHH86
G70WDO-T4F
(G14, H41, H66, J48)
477986UHAAG14
513023UHAHJ48
Audience:
Dealers, National Rental Accounts
Issue:
For the units with electrical brake and battery disconnect options installed and listed on this bulletin, it has been identified that the electric brake harness connection may be connected to the positive distribution lug of the battery disconnect switch instead of the positive battery cable terminal. If connected in this manner and the battery disconnect switch is in the off position, the emergency electric brakes will be deenergized.
1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 2 of 3
Solution:
To correct, please see instructions that follow:
• Disconnect positive battery cable from battery using 1/2” wrench. (Fig. 1)
Fig. 1
• Remove metal cover around disconnect switch to expose positive distribution connection (Fig. 2)
z
Fig. 2
• Cut any zip ties that secure the electric battery harness.
• Loosen and remove distribution nut using 9/16” wrench.
• Remove electric brake harness from positive distribution lug.
• Reinstall distribution nut and secure using 9/16” wrench.
• Replace metal cover around disconnect switch.
1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 3 of 3
• Remove nut from positive battery cable battery terminal using 1/2” wrench (Fig. 3).
Fig. 3
• Install electric battery harness ring terminal onto battery terminal bolt and reinstall nut.
• Install positive battery cable terminal on battery positive post and secure nut tightly on battery terminal using 1/2” wrench. • Verify electric brake solenoids are operating with battery disconnect in the OFF position.
Warranty:
Campaign 12-23-8 is active in the warranty system for each potentially affected unit.
1 hour of labor approved for moving electric brake harness and verifying electric brake solenoid.
All claims must be submitted as claim type = “Field Modification”
The causal part = 46556146
Campaign will be valid until December 31, 2026
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1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 1 of 5
IMPORTANT SAFETY RECALL
April 3, 2024
Safety Recall Notice 12-23-8 Rev. A /NHTSA Recalls 23V859 & 24V230
Dear Doosan Bobcat Portable Power Dealer,
This Notice applies to your Doosan Bobcat North America, Inc. Product:
G25WDO-T4F (G06), G50WDO-T4F (F90), G70WDO-T4F (G14) Your Unit Serial Number: See table at end of notice for list of affected units
This Notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Doosan Bobcat North America, Inc. has decided that a defect, which relates to vehicle safety, exists with certain 2015 thru 2023 Doosan Portable Power Generators that have both electric brake and battery disconnect options installed. The Unit Serial Number of the specific affected unit is provided above.
We apologize for this inconvenient situation and want to assure you that, with your support and the support of your Doosan Bobcat Portable Power Dealer, we will correct this issue. We are committed to your satisfaction and together with your dealer our intent is to provide you with the industry-best level of service and support.
What is the issue? For the units with both the electric brake and battery disconnect options installed and listed on TSB 12-23-8 Rev A, it has been identified that the electric brake harness connection may be connected to the positive distribution lug of the battery disconnect switch instead of the positive battery cable terminal. If connected in this manner and the battery disconnect switch is in the off position, the emergency electric brakes will be deenergized. Deenergized brakes will not engage, increasing the risk of a crash.
What should you do? 1. Immediately stop towing the unit and notify others not to tow it until the potential issue has been corrected. The unit can still be operated in a stationary position but must not be towed. 2. Contact your local Doosan Bobcat Portable Power dealer and request a service date for TSB 12-23-8.
1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 2 of 5
If you do not have a local servicing dealer or you do not know who the local servicing dealer is, you can access https://www.doosanportablepower.com/na/en/support/find-a-dealer for dealer address, maps, and driving directions.
What will Doosan Bobcat North America, Inc. and your dealer do?
Doosan Bobcat Portable Power dealers are authorized to inspect and repair any damaged components found related to TSB 12-23-8. This safety campaign will be performed free of charge to the unit owner (parts, travel time/mileage, and labor).
How long will it take?
The time needed to complete this inspection/repair is approximately 1 hour. However, due to service time availability, and travel schedule to the unit, additional time may be needed to complete repairs.
Have you previously paid for this repair?
If you have previously paid for repairs associated with the issue described in this letter you still need to have this recall performed to ensure the correct procedures were used.
You may be eligible for a refund for previously paid repairs. Refunds will only be provided for issues related to TSB 12-23-8. To verify eligibility for a refund, present all your receipts of the repairs along with any available photos or write up of the issues.
Your Servicing Doosan Bobcat Portable Power Dealer will request a refund on your behalf to Doosan Bobcat North America, Inc. Refunds could take up to 60 days to process.
What if you no longer own this Doosan Bobcat Portable Power Unit?
If you no longer have this product, we ask that you contact us with its disposition so we can contact the new owner. Contact Doosan Bobcat Portable Power Technical Service at 1-800-633-5206 Option #2. You received this recall letter because government regulations require that notification be sent to the last known owner of record. Our records indicate that you are the current owner.
Can we assist further?
If you have difficulties getting your Doosan Bobcat Portable Power unit repaired promptly at no charge to you, please contact your local dealership’s Service Manager for assistance.
1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 3 of 5
If you wish to contact us directly for support in this matter, please call 1-800-633-5206 Option #2 to speak with a Doosan Bobcat Portable Power Representative. Representatives are available Monday-Friday: 8:00AM – 6:00PM (Eastern Time).
If after contacting Doosan Bobcat North America, Inc. you are still not satisfied that the remedy was done at no charge or in a timely manner, you may submit a written 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.
Thank you for your attention to this matter.
Yours truly,
Shawn Warkenthien
Senior Director Global Product Safety & Compliance
1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 4 of 5
Table of Affected Units
S/N
PO
473915UJZG06
6943880
473916UJZG06
6943881
475856UDAAF90
6943887
475858UDAAF90
6943888
476229UDAAF90
6943889
476230UDAAF90
6943890
476231UDAAF90
6943891
476232UDAAF90
6943883
476233UDAAF90
6943884
476234UDAAF90
6943885
476235UDAAF90
6943886
485317UCACG14
8675531
491866UCADG06
10764822
492094UCADG06
10764822
492096UCADG06
10764822
492097UCADG06
10764822
492098UCADG06
10764822
492100UCADG06
10764822
492101UCADG06
10764822
492102UCADG06
10764822
492103UCADG06
10764822
492384UCADG06
10764822
492595UCADG06
10764822
492742UCADG06
10764822
492743UCADG06
10764822
492844UDADG06
10764822
492845UDADG06
10764822
492846UDADG06
10764822
492847UDADG06
10764822
492848UDADG06
10764822
492849UDADG06
10764822
492850UDADG06
10764822
492851UDADG06
10764822
492873UDADF90
10764822
492874UDADF90
10764822
1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
Page 5 of 5
492875UDADF90
10764822
492876UDADF90
10764822
492877UDADF90
10764822
492878UDADF90
10764822
492879UDADF90
10764822
492880UDADF90
10764822
492881UDADF90
10764822
492882UDADF90
10764822
492883UDADF90
10764822
494001UEADG06
10764822
494806UGADG06
10764822
494807UGADG06
10764822
494808UGADG06
10764822
494809UGADG06
10764822
494810UGADG06
10764822
494811UGADG06
10764822
494812UGADG06
10764822
494813UGADG06
10764822
494814UGADG06
10764822
494815UGADG06
10764822
494816UGADG06
10764822
494817UGADG06
10764822
494818UGADG06
10764822
494832UGADF90
10764822
494833UGADF90
10764822
494834UGADF90
10764822
494835UGADF90
10764822
494836UGADF90
10764822
494837UGADF90
10764822
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1293 Glenway Drive
Statesville, NC 28625
T: 800-633-5206
SAFETY NOTICE – PLEASE READ IMMEDIATELY
March 23, 2024
Doosan Bobcat North America, Inc. is sending this Safety Notice to certain owners of various models of portable generators built between 2015 and 2023 that have both electric brake and battery disconnect options installed and are listed in Technical Service Bulletin 12-23-8 Rev. A. This notice alerts owners to a safety concern explained below.
For the units with both electric brake and battery disconnect options installed and listed on this bulletin, it has been identified that the electric brake harness connection may be connected to the positive distribution lug of the battery disconnect switch instead of the positive battery cable terminal. If connected in this manner and the battery disconnect switch is in the off position, the emergency electric brakes will be deenergized. Deenergized brakes will not engage, increasing the risk of a crash.
We are reporting this issue to the National Highway Traffic Safety Administration (NHTSA). Federal Regulations require you to complete this safety campaign and per the Doosan Bobcat North America, Inc. Warranty Policy and Procedure Manual, you are obligated to complete the requested work within 60 days.
We request that you immediately:
1. Read the attached Safety Recall addressed to owners.
2. Contact all owners of affected portable generators and arrange to correct their machines. This will be done at no cost to the owner. Inform them that the equipment can be operated in a stationary position but must NOT be towed until the corrections are made.
3. Stop Sale/Stop Rental on all new and used portable generator affected by this campaign until they have been corrected.
4. Stop towing the affected equipment until the corrections are made.
Thank you for your attention to this matter. If you have any questions about this Safety Recall, please call Doosan Bobcat Portable Power Technical Services at 1-800-633-5206 Option #2
Yours truly,
Shawn Warkenthien Senior Director Global Product Safety & Compliance
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SEOCONTENT-END
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