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July 3, 2020 NHTSA CAMPAIGN NUMBER: 20V394000
Engine Compartment Flap Hinge Improperly Welded
If the engine compartment flap detaches from the coach while it is in motion, it can become a projectile, increasing the risk of a crash.
NHTSA Campaign Number: 20V394
Manufacturer Daimler Coaches
North America
Components STRUCTURE
Potential Number of Units Affected 55
Summary
Daimler Coaches North America (DCNA) is recalling certain 2018-2019 Setra S407 and 2019-2020 S417 passenger coaches. The engine compartment flap may not have sufficient welding seams on the hinges, allowing the hinge connection to fail and the engine compartment flap to detach from the coach.
Remedy
DCNA will notify owners, and dealers will inspect the engine compartment flap seam welds and, if necessary, re-weld or replace the engine compartment flap, free of charge. The recall began August 28, 2020. Owners may contact DCNA customer service at 1-905-403-7807. DCNA’s number for this recall is 75.00U20104A.
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.
COMPLAINT
The weld seams on the brackets of the engine compartment flap were not executed fully.
CAUSE
Error in the documentation.
REMEDY
Check the weld seams on the brackets of the engine compartment flap against the latest documentation and, if necessary, incorporate the missing weld seams.
If the weld seams cannot be incorporated, the engine compartment flap must be replaced with a new one.
MEASURE TYPE
The scope of the work is carried out as part of a safety recall (RC).
REPLACEMENT PARTS REQUIRED
| Quantity | Designation | Number | Comment |
| 1 | Engine compartment flap | A 629 750 40 33 | Only if required |
Procedure
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.
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.
Warning
Risk of entrapment and crushing. Danger to hands, arms and legs during all work on doors, flaps, covers and roof hatches.
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.
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.
Warning
Risk of fatal injury. Risk of fatal injury due to high voltages present during electric arc welding. Risk of explosion when welding near highly flammable materials. Risk of injury from welding spatter and ultraviolet light during welding. Risk of poisoning from inhalation of welding fumes. Welding sparks and splashes of liquid weld matter could cause severe burns if they come into contact with unprotected parts of the body. The ultraviolet light emitted during electric arc welding may cause damage to the eyes and burn unprotected skin. If electric welding work is carried out in a damp environment or on a wet surface, there is a risk of fatal injury as the voltage may be discharged through the human body. This could cause severe burning, cardiac fibrillation or heart failure. Standard work clothes (made of cotton or synthetic fibres) may catch fire due to welding sparks and splashes of liquid weld metal, and inflict very severe burns as a result.
Caution
Irreparable damage due to overvoltage and risk of fire. Measures required for the prevention of damage to buses or components during electric welding work. In order to prevent damage, the following measures should be carried out before the commencement of welding work:
Warning
Risk of explosion and poisoning. Risk of explosion and of poisoning from solvent vapours and gases. There is a risk of injury to the eyes and skin when handling corrosion inhibitors. Do not spray corrosion inhibitor onto naked flames or red-hot materials. Keep corrosion inhibitor away from sources of ignition at all times. Carry out the work in well-ventilated rooms and wear respiratory protection.
Warning
Risk of accident. Danger from unauthorised starting of the engine or movement of the vehicle. Persons in areas of the bus that are hidden from view (underbody, rear, roof, etc.) are at risk of injury if the engine is started or the vehicle is moved by other or unauthorised persons.
Checking the weld seams
- Open the engine compartment flap.
- Check the weld seams on the brackets of the engine compartment flap against the latest documentation. Result 1 / 2
All weld seams present in accordance with the documentation.
โถ No further work necessary, close the engine compartment flap.
Result 2 / 2
Not all weld seams are present in accordance with the documentation.
โถ Remove the engine compartment flap and incorporate the missing weld seams in accordance with the documentation.
Completing the weld seams
- Abrade the weld area down to bright metal and clean.
| Required material |
| Pneumatic brush grinder
Model: MBXยฎ Metal Blasterยฎ |
- Cover or mask off adjacent areas extensively and provide protection against flying sparks.
- Incorporate the missing weld seams to a professional standard.
Note
To ensure that the optimum welder setting is used, it is advisable to perform a test weld on a scrap sheet beforehand.
- Remove burn-off deposits and clean the welding point.
| Required material |
| Pneumatic brush grinder
Model: MBXยฎ Metal Blasterยฎ |
- Apply primer and corrosion inhibitor.
Note
Observe the application information and drying times of the paint manufacturer.
Fitting and adjusting the engine compartment flap
Note
Whenever you are adjusting flap gap dimensions, always take into consideration (adapt to) the gap dimensions of adjacent components.
Note
The following priorities govern the adjustment of exterior flaps: Priority 1: leak-tightness of the flaps. Priority 2: gap dimensions, appearance of the gap line and evenness of the outside of the flap surface in closed condition. Priority 3: gap dimensions, position and evenness of the outside of the flap surface in open condition.
- โ
| Reference values | |
| Engine compartment flap gap dimension (D) | 6 โฆ 10 mm |
| Reference values | |
| Uniform gap line from (1.1) to (1.2), permissible deviation | 1.5 |
Note
Adjust all gaps around the engine compartment flap in such a way that their dimensions are as equal as possible. The maximum relative deviation is 1.5 mm.
- โ
| Reference values | |
| Transitions (planar alignment) (E) from the outer surface to all adjacent components | 0+1.5+1.5 mm |
SEOCONTENT-START
12.8.2020
1/6
Technical
information
TI No.: 75.00U20104A Distribution list: D Distribution date:
12.08.2020
Valid until: 31.12.2040
The point of contact is the EvoBus after-sales service in each country
Model: TC 400 USA
MODEL SERIES: 629540; 629557
TITLE: TC 400 USA – completing the weld seams on the brackets of the
engine compartment flap
OPERATION TEXTS
Operation no. Operation text Working time/h Comment
02-1920 Check weld seams on brackets of engine
compartment flap
0.2
02-1921 Remove and fit engine compartment flap
(after check)
1.2 Associated work for 02-1920
Operation no. Operation text Working time/h Comment
02-1922 Complete weld seams on brackets of engine
compartment flap (engine compartment flap
removed)
2.5 Associated work for 02-1921
The times apply for work at an hourly rate.
DEFECT NUMBER
Defect no.: Designation
7591065
CODEWORD
7500U20104
INTRODUCTION OF MODIFICATIONS INTO SERIES PRODUCTION
01.02.2020
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
*********************************************************************************************************
Daimler Coaches North America
2477 Deerfield Drive
Fort Mill, SC. 29715
August 28, 2020
A Yankee Line Inc
Attn: Donald Ogden
370 West First St
Boston MA 02127
IMPORTANT SAFETY RECALL
This notice applies to your vehicle
WKKA404 WKKA574 WKKA574 WKKA574
WKKA404 WKKA574 WKKA574 WKKA574
WKKA404 WKKA574 WKKA574 WKKA574
WKKA404 WKKA574 WKKA574 WKKA574
WKKA574 WKKA574 WKKA574 WKKA574
WKKA574 WKKA574
SUBJECT: SAFETY RECALL OF 2018~2020 SETRA S407 & S417TC COACHES
Ref.: NHTSA recall reference # 20V-394
Setra Bulletin # TI 75.00U20104A
Dear Setra Owner,
This notice is sent to you in accordance with the requirements of the U.S. National Traffic and Motor Vehicle
Safety Act.
EvoBus GmbH (the manufacturer of Setra coaches) has decided that a defect (details below) which relates to
motor vehicle safety exists in certain 2018~2019 Setra S407 and certain 2019~2020 Setra S417 vehicles.
EvoBus therefore has initiated a recall of these vehicles. Our records indicate that your vehicle is included in
this group.
Due to an error in manufacturing, the welding on the hinge mounting of the engine compartment flap could be
incomplete. This could reduce the overall strength and stability of the hinge possibly resulting in the engine
compartment flap becoming detached. A detached engine compartment flap could increase the risk of injury or
a crash.
Setra will remedy this by inspecting the welding seams on the hinge mountings of the engine compartment flap
and, if necessary, re-weld or replace the engine compartment flap. This repair will be performed free of charge.
Details are outlined in the repair procedure number TI 75.00U20104A. Please allow for up to three (3) hours to
schedule and complete the repair.
Please contact DCNA Customer Service Line at 1-800-206-9728 if you need further information.
Setra strongly urges you to perform the recall inspection work on your vehicle(s) as soon as possible.
Daimler Coaches North America
2477 Deerfield Drive
Fort Mill, SC. 29715
For reimbursement of the repair, please submit a completed Setra Warranty Claim Form or refer to TI bulletin
75.00U20104A for complete details;
US Mail Email
Daimler Coaches North America (DCNA) DCNAWarranty@daimler.com
Attn: Shelly Bontrager
238 Oak Street,
Millersburg, IN. 46543
After contacting Setra Customer Service, if you are still unable to have the safety defect remedied without
charge and within a reasonable time, you may submit a complaint to:
For US customers:
You may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200
New Jersey Avenue, SE, Washington, DC 20590, or call 888 327-4236 (TTY: 800-424-9153), or go to
https://www.safercar.gov if remedy difficulties exist.
If you are no longer the vehicle owner, or have had a change of address, please complete the reverse side of this
letter and return the complete letter in the enclosed envelope. If this is a leased vehicle and the lessor and
registered owner receive this notice, Federal law requires any lessor who receives a notification of a
determination of a safety-related defect or noncompliance pertaining to any leased motor vehicle shall send the
notice to the lessee within 10 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.
Please contact your authorized Setra dealer should you have any questions or encounter any difficulty regarding
this recall. If your dealer is unable to remedy your situation, please contact us at our Setra Customer Service
Line at 1-800-206-9728 if you have any questions about this recall.
We apologize for any inconvenience this situation may cause you.
Sincerely
Daimler Coaches North America
Warranty Department
Daimler Coaches North America
2477 Deerfield Drive
Fort Mill, SC. 29715
IMPORTANT
IF FOR ANY REASON YOU DO NOT NOW OWN THIS VEHICLE OR HAVE A CHANGE OF ADDRESS, PLEASE COMPLETE THE SECTION BELOW,
PLACE IN THE ENCLOSED ENVELOPE, AND DROP IN ANY MAIL BOX. IF POSSIBLE, PROVIDE THE NAME AND ADDRESS OF THE PRESENT
OWNER SO THAT WE MAY CONTACT THEM.
๏ฑ SCRAPPED
๏ฑ STOLEN
๏ฑ OTHER
๏ฑ SOLD I HAVE SOLD THE VEHICLE TO:
๏ฑ MY NEW ADDRESS IS:
NAME
STREET APT.
CITY STATE ZIP
PHONE
THANK YOU FOR YOUR COOPERATION
**** PLEASE DO NOT DETACH. RETURN COMPLETE LETTER ****
DO NOT USE THE ENCLOSED ENVELOPE FOR OTHER CORRESPONDENCE
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, labor, fees and taxes. Reimbursement may be limited to the amount
the repair would have cost if completed by an authorized Setra dealer. The following documentation must be
presented to your dealer for reimbursement.
Original or clear copy of all receipts, invoices and/or repair orders that show:
๏ท The name and address of the person who paid for the repair.
๏ท The Vehicle Identification Number (VIN) of the vehicle that was repaired.
๏ท What problem occurred, what repair was done, when it was done and who repaired it.
๏ท The total cost of the repair expense that is being claimed.
๏ท Proof of payment of repair (copy of front and back of cancelled check, or copy of credit card receipt).
๏ท Reimbursement will be made by check from your dealer. If your claim is denied you will receive a letter from
Setra within 60 days of receipt with the reason(s) for the denial.
Please speak with your dealer concerning this matter.
SEOCONTENT-END
4 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| SETRA | S407 CC | 2018-2019 |
| SETRA | S417 TC | 2019-2020 |
10 Associated Documents
Recall Acknowledgement
RCAK-20V394-6881.pdf 245.074KB
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Defect Notice 573 Report
RCLRPT-20V394-5411.PDF 213.844KB
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Defect Notice 573 Report
RCLRPT-20V394-8594.PDF 213.85KB
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Recall Quarterly Report #3, 2021-1
RCLQRT-20V394-0290.PDF 211.326KB
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Recall Quarterly Report #2, 2020-4
RCLQRT-20V394-7581.PDF 211.248KB
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Owner Notification Letter(Part 577)
RCONL-20V394-6799.pdf 731.506KB
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Remedy Instructions and TSB
RCRIT-20V394-7193.pdf 402.61KB
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Recall Quarterly Report #1, 2020-3
RCLQRT-20V394-6480.PDF 211.145KB
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Recall 573 Report- Amendment 1
RCLRPT-20V394-7613.PDF 216.888KB
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Recall Quarterly Report #4, 2021-2
RCLQRT-20V394-8350.PDF 211.439KB
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