April 2, 2020 NHTSA CAMPAIGN NUMBER: 20V190000

Front Door May Open or Detach While Driving

A detached door can increase the risk of injury to the coach occupants or the detached door could be a road hazard, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V190

Manufacturer Daimler Coaches North America

Components STRUCTURE

Potential Number of Units Affected 63

 

Summary

Daimler Coaches North America (Daimler Coaches) is recalling certain 2017-2020 Setra S417TC coaches. The front entrance door support frame may not be the correct size, and, as a result, the door may open and may detach from the vehicle while the coach is moving.

 

Remedy

Daimler Coaches will notify owners, and dealers will replace the front entrance door support frame and holders at the base of the support frame, free of charge. The recall is expected to begin May 29, 2020. Owners may contact Daimler Coaches customer service at 1-416-624-3558. Daimler Coach’s number for this recall is 72.00M20089A.

 

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.safercar.gov.

 

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Technical information

TI No.: 72.00U20089A

Distribution list: D

Distribution date: 20.05.2020 Valid until: 31.12.2040

 

The point of contact is the EvoBus after-sales service in each country

 

Model:	TC 400 USA
MODEL SERIES:	629557
TITLE:	TC 400 USA – Replacing the support arm at door I

 

COMPLAINT

In strong gusts of wind, door I lifts up while the bus is in motion.

 

CAUSE

Inadequate dimensional accuracy of the welded support arm variant.

 

REMEDY

Exchange the support arm and angle mounting at door I for optimised variants.

 

MEASURE TYPE

The scope of the work is carried out as part of a safety recall (RC).

 

DEFECT PART HANDLING

The GALA (warranty parts processing) stipulations are binding. Workshops without GALA should scrap the defect parts immediately after the repair.

 

REPLACEMENT PARTS REQUIRED

Quantity	Designation	Number	Comment
1	Support arm	A 629 760 17 73 05
2	Coupling screw	A 010 990 91 04 05
3	Hexagon nut	N 910112 010001
4	Washer	N 000000 008842
1	Angle mounting	A 629 723 02 12 05
2	Screw M8x30	N 000000 001388
2	Blind rivet nut	A 001 990 41 59 05	Only if required

 

OPERATION TEXTS

Operation no.	Operation text	Working time/h	Comment
02-1782	Replace support arm of passenger door with new one	2.9	Includes adjustment work

 

The times apply for work at an hourly rate.

 

DEFECT NUMBER

Defect no.:	Designation
7290074

 

CODEWORD

7200U20089

 

INTRODUCTION OF MODIFICATIONS INTO SERIES PRODUCTION

Batch problem

 

WARRANTY AND GOODWILL SETTLEMENTS

Field measure type RC: 100 % of costs will be accepted.

BUS/MCC	BUS/MCC-O
pp.	pp.
Johannes Lehmann	Markus Fischer

 

Attachments

Procedure

Warning

Risk of injury. During work on doors, there is a risk of pinch point injuries or entrapment of individual limbs, e.g. hands, arms or legs. The following points must be observed during work on the doors, flaps, covers and roof hatches.

Details…

 

Warning

Risk of entrapment and crushing. Danger to hands, arms and legs during all work on doors, flaps, covers and roof hatches.

Details…

 

Warning

Risk of entrapment and crushing. Reaching in between mechanically operated parts may result in serious injuries due to the severing or crushing of body parts.

Details…

 

Warning

Risk of entrapment and crushing. Danger to fingers and hands when the power supply is connected.

Details…

 

Warning

Risk of injury. Danger due to the dropping of unwieldy or heavy components. The unforeseen dropping of components can result in serious injuries to the body and limbs.

Details…

 

Warning

Risk of accident. Danger when lifting and transporting heavy components. The use of defective or unsuitable lifting equipment and hoists for the lifting and transporting of heavy components could result in serious or fatal injuries to all persons involved if the component were to drop or slip.

Details…

 

Warning

Risk of injury. Danger from the spontaneous opening or dropping of flaps, doors, covers and panels. There is a risk of flaps, doors, covers or panels that have been closed or fitted incorrectly opening or coming loose spontaneously, especially while the vehicle is in motion, and thereby causing injury.

Details…

 

Preparatory tasks

1. Ignition starter switch to position 0 (ignition OFF).
2. Turn the emergency valve as far as the stop in the direction of the arrow.

 

Procedure

Loosening the lower linkage

1. Remove ball joint (2) of linkage (1).

 

Removing the door leaf

1. Remove nut (2) and washer (3).
2. Remove cover (2).
3. Remove, release and disconnect the electrical connection of the pressure shaft switch.
4. Support the door leaf using an assembly lifter.
5. Unscrew screws (4).
6. Remove the door leaf upwards.

Note

Set the door leaf down on a suitable underlay and protect it from damage.

7. On the door leaf, check that the blind rivet nuts for securing the angle mounting and firmly seated.

Note

If necessary, the blind rivet nuts must be replaced with new ones to a professional standard.

 

Removing the support arm

1. Remove cover (2) from the upper mounting console.
2. Remove cover (3) from the door drive.
3. Loosen lock nut (8) from bearing pin (7).
4. Fully unscrew bearing pin (7).
5. Colour-mark the position of door drive (8) on lower mounting console (9) as illustrated.
6. Unscrew screws (10) and remove door drive (8) together with support arm (11).

 

Replacing and fitting the support arm

Tightening torque Door rotating pillar to door drive
M8 × 33	28 Nm

 

7. Unscrew coupling screws (4).
8. Remove support arm (6) from door drive (3).
9. Position new support arm (6) on door drive (3).
10. Hold support arm (6) in position using new coupling screws (4).
11. Remove the coil spring and guide sleeve from the removed support arm and fit them to the new support arm.
12. Align door drive (8) and support arm (11) with applied markings (9) and secure using screws (10).

Tightening torque
Door drive to bodywork	46 Nm

 

13. Insert bearing pin (7) and screw down until groove (9) of the bearing is flush with the top edge of rotating pillar tube (6).
14. Secure the position of bearing pin (7) by tightening lock nut (8).

Tightening torque Lock nut for upper door mounting bearing pin
Hexagon nut M20 × 1.5 ‒ -04- DIN 439	54.0 Nm

 

Fitting the door leaf

15. On support tube (1), fit a hexagon nut (2) and washer (3).
16. Position the door leaf with upper angle bracket (6) on support tube (1) and screw it on with washer (4) and hexagon nut (5).

Tightening torque Tubular bracket
M10 ‒ 8,8	46 Nm

 

17. At the bottom end of support tube (1), fit new angle mounting (7) with washers (8) and hexagon nut (9).
18. Secure angle mounting (7) to the door leaf using new screws (10).

Tightening torque
Angle mounting to door leaf	23 Nm

 

Note

If it is not possible to secure to the specified torque because the blind rivet nuts are loose, the blind rivet nuts must be replaced with new ones to a professional standard.

 

Note

The new angle mounting must not be overpainted.

19. Secure angle mounting (7) to support tube (1) using nut (9).

Tightening torque Tubular bracket
M10 ‒ 8,8	46 Nm

 

20. Connect the electrical connection for the pressure shaft switches and fit it into the door leaf.

 

Fitting the lower linkage

1. Secure guide arm (1) to bracket (2).

Tightening torque Lower guide arm to vehicle underside
Hexagon nut	35 Nm

 

Inspection and adjustment work

Note

Due to the wide variety of door systems, it is not possible to provide an exact guide for a particular vehicle.

Example instructions can be found in BusDoc 35.51 TC 500. The variant on a particular vehicle may differ from the illustrations shown here.

21. Adjust the door leaf.
22. Adjust the rotating pillar drive.
23. Adjust door speed.
24. Adjust end position damping.
25. Adjust the striker pins.

 

Finishing tasks

1. Fit all covers.
2. Updating vehicle documentation in the “VeDoc” system and updating bus-specific electrical data

 

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4 Affected Products

Vehicle

MAKE	MODEL	YEAR
SETRA	S417 TC	2017-2020

 

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5 Associated Documents

Remedy Instructions and TSB

RCRIT-20V190-6027.pdf 926.15KB

 

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Recall Acknowledgement

RCAK-20V190-5453.pdf 245.461KB

 

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Defect Notice 573 Report

RCLRPT-20V190-6807.PDF 214.205KB

 

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V190-5519.PDF 211.335KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V190-2911.PDF 211.248KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V190&docType=RCL

 

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