October 30, 2020 NHTSA CAMPAIGN NUMBER: 20V670000
Inverter may be Wired Incorrectly
If the inverter is turned on, and energizes the shore power connection, it can increase the risk of injury.
NHTSA Campaign Number: 20V670
Manufacturer Keystone
RV Company
Components EQUIPMENT
Potential Number of Units Affected 1,278
Summary
Keystone RV Company (Keystone) is recalling certain 2020-2021 Cougar trailers equipped with the Off the Grid (OTG) Solar package. The inverter may have been incorrectly wired, causing power to energize the shore power connection, when in use.
Remedy
Keystone will notify owners, and dealers will test the function of the inverter and rewire it as needed, free of charge. The recall began November, 18, 2020. Owners may contact Keystone customer service at 1-866-425-4369. Keystone’s number for this recall is 20-389.
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.
12/15/20
Keystone RV Company
SAFETY ADVISORY # 20-389
Cougar Inverter Wiring
Keystone is conducting a voluntary RECALL notification campaign in accordance with the National Highway Transportation and Safety Act. It has been decided that the vehicles in the recall population have an inverter that may have been incorrectly wired and when in use is allowing power to energize the shore power connection. When the incorrectly wired inverter is turned on, 120VAC power will energize the shore power connection leading to an increased risk of personal injury.
| Models Included: | 2020 – 2021 Cougar Fifth Wheel and Travel Trailers: 22RBSWE, 24SABWE, 25BHSWE, 26RBSWE, 27RESWE, 27SABWE, 29BHSWE, 29RLDWE, 29RLKWE, 29RLSWE, 30RKDWE, 31BHKWE, 32RDBWE, 24RDS, 25RES, 27SGS, 29MBS, 29RKS, 302RLS, 307RES, 30RLS, 315RLS, 316RLS, 32BHS, 353SRX, 364BHL, 366RDS, 367FLS, 368MBI, 361RLW |
| Serial Number Ranges: | 2020
L2502429 – L2509218 LC503863 – LC509167
2021 M2500058 – M2505320 MC500000 – MC502509 |
| Local Parts: | – Wiring Connectors – Romex Wiring (only when needed) |
| Tools Required: | – Screw gun – Screwdriver – Wire Cutter/Stripper |
Note – Check serial number on Key Express to verify the campaign is open. Some vehicles were repaired before they left Keystone.
When performing warranty or recall service, please make certain that appropriate Personal Protective Equipment (PPE) is used.
The remedy is to test the function of the inverter. The only outlets that should be energized are the outlets marked “Off the Grid Inverter Circuit”. If other outlets or appliances are energized, or only one outlet is energized, the connection at the inverter must be inspected and repaired as needed.
REPAIR INSTRUCTIONS
Step 1
Locate the trailer on a level, flat, hard surface. Chock the wheels.
Step 2
With a fully charged battery connected; disconnect the shore power and turn on the inverter. Inspect outlets labeled “Off the Grid Inverter Circuit”. These should be the only 120VAC circuits energized in the unit. See Figure 1. If these are the only circuits energized proceed to Warranty Reimbursement for inspection only, otherwise proceed to Step 3.
Step 3
If only one outlet labeled “Off the Grid Inverter Circuit” is energized proceed to step 5. If other circuits or appliances are energized other than those labeled “Off the Grid Inverter Circuit” proceed to Step 4.
Step 4
All serial numbers listed above could be potentially affected by this scenario. If other circuits are energized verify the inverter input and output connections are not reversed. If the connections are reversed, disconnect 120VAC and 12VDC power to the unit, repair the connections and test the function of the inverter. If inverter function is correct (as in Step 2 and Figure 1), proceed to Warranty Reimbursement below. If only one outlet labeled “Off the Grid Inverter Circuit” is energized proceed to step 5.
Step 5
Only West Coast units with Serial numbers starting with LCXXXXXX and MCXXXXXX are potentially affected by this scenario. If only one outlet labeled “Off the Grid Inverter Circuit” is energized See Figure 2. Disconnect the 120VAC power and the 12VDC power. Remove the power center and disconnect the wiring to the breaker labeled as “Inverter” along with the neutral and the bare copper wire for this circuit out of the power center.
Step 6
Locate the inverter in the front pass through. Remove the 14-2 Romex input and the 14-2 output wiring from the inverter and connect them together in a 2”x4” junction box near the inverter. See Figure 3.
Step 7
Utilizing the shortest/fastest route, install two new 14-2 Romex wires from the power center to the inverter. Mark one of the wires input and one wire output at each end. Remove the fasteners in a couple of spots in the underbelly to run the wire from the power center to the off-door side front corner. Fasten the Romex to cross members whenever possible using zip ties (shop supplied part).
Step 8
Remove the lower metal on the front wall. Install and secure the two 14-2 Romex wires from the power center through the front wall framing into the pass-through inverter prep area. Once the two 14-2 Romex wires are run into the inverter prep area, the lower front metal can be reinstalled and properly sealed to prevent water intrusion. Refasten the underbelly.
Step 9
At the inverter install the input and output 14-2 Romex wires from step 8 into the inverter as labeled.
Step 10
Install a 2”x4” junction box in the area behind the power center and connect the newly installed 14-2 Romex wire labeled output and the previously removed 14-2 Romex wire from the inverter breaker in Step 5. Install cover on the junction box. See Figure 3.
Step 11
Install the newly ran Romex 14-2 wire labeled as input into the power center. Attach the black load wire to the inverter breaker, attach the neutral wire to the neutral buss bar, and attach the bare copper wire to the ground buss bar. Reinstall power center and test inverter function.
Step 12
Proceed to Warranty Reimbursement.
WARRANTY REIMBURSEMENT
INSPECTION ONLY
Submit a claim on Key Express using Flat Rate Code # 7138942F
In the Complaint section note: Safety Advisory # 20-389
In the Cause section note: Safety Advisory # 20-389
In the Correction section note: Inverter tested and working as designed
The amount of time authorized for this repair is .3 hour.
REPAIR
Submit a Pre-Authorization request then claim on Key Express using Flat Rate Code # 7138942A
In the Complaint section note: Safety Advisory # 20-389
In the Cause section note: Safety Advisory # 20-389
In the Correction section note:
Inverter tested, Input and Output wires were reversed. Rewire inverter and tested for proper operation.
Or
Inverter tested only one outlet was energized by inverter.
Add junction boxes, 14-2 Romex and rewire inverter.
The amount of time authorized for reversed wiring at the inverter as outlined in Step 4 is 0.7 hour.
The amount of time authorized for incorrectly wired circuits for inverter as outlined in Step 5 is 4.5 hours. Only serial numbers LC503863 – LC509167 and MC500000 – MC502509 built on the west coast may potentially have this condition.
PARTS DISPOSITION
No Part Return.
Please call Keystone RV Customer Service at (866) 273-1454 if you have any questions.
SEOCONTENT-START
PO Box 2000 – Goshen, IN 46527-2000
Phone: (574) 535-2100 – Fax: (574) 535-2199
www.keystonerv.com
Recall Population
2020 – 2021 Cougar Fifth Wheel and Travel Trailers
Models: 22RBSWE, 24SABWE, 25BHSWE, 26RBSWE, 27RESWE, 27SABWE, 29BHSWE, 29RLDWE, 29RLKWE, 29RLSWE, 30RKDWE, 31BHKWE, 32RDBWE, 24RDS, 25RES, 27SGS, 29MBS, 29RKS, 302RLS, 307RES, 30RLS, 315RLS, 316RLS, 32BHS, 353SRX, 364BHL, 366RDS, 367FLS, 368MBI, 361RLW
Serial Number Ranges:
2020 L2502429 – L2509218
LC503863 – LC509167
2021 M2500058 – M2505320
MC500000 – MC502509
Keystone RV Company has decided that a defect which relates to motor vehicle safety exists in the vehicles listed above. As a result, Keystone RV is conducting a safety recall. We apologize for any inconvenience this action may cause you; however your safety and continued satisfaction are of the utmost importance to us.
It has been decided that the vehicles in the recall population have an inverter that may have been incorrectly wired and when in use, is allowing power to energize the shore power connection. When the incorrectly wired inverter is turned on, 120VAC power will energize the shore power connection leading to an increased risk of personal injury.
Keystone representatives have been in contact with the staff at your selling dealership regarding this situation. The remedy is test the function of the inverter and rewire as needed. The service and parts required for this corrective action will be provided at no charge to you.
If the inverter is turned on and any circuits other than the “Off The Grid Inverter Outlet” circuit is powered on then turn off the inverter and have the system inspected by an authorized dealer. As soon as possible, please make an appointment to have your RV serviced by your dealership. The labor time to perform this correction is approximately 1 hour. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your RV for this repair.
Your dealer is best equipped to obtain parts and provide service to ensure your RV is corrected as promptly as possible. Please contact Keystone Customer service if your dealer is unable to assist or if you take your RV to your dealer on the agreed service date, and the dealer does not remedy the condition within a reasonable amount of time, or without charge to you. You may be eligible to receive reimbursement if you paid to have the defect resolved prior to receiving this correspondence. Keystone Customer Service is available toll-free at 1-866-425-4369.
If after contacting Keystone Customer Service you are still not satisfied we have done our best to remedy this situation, you may also submit a written complaint to: Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590. You may call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153; or go to https://www.safercar.gov.)
Reason for this recall
What we will do
What we need you to do
If you have questions
RECREATIONAL VEHICLE SAFETY RECALL NOTICE
Safety Recall: 20V-670
Safety Advisory: 20-389
Transport Canada: 2020-526
November 18, 2020
*************************************************************************************************************
PO Box 2000 – Goshen, IN 46527-2000
Phone: (574) 535-2100 – Fax: (574) 535-2199
www.keystonerv.com
IMPORTANT SAFETY RECALL
«Owner_name»
«Street»
«Street_2»
«City», «State» «Zip»
This notice applies to your vehicle: «VIN»
Dear «Owner_name»:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Keystone RV Company has decided that a defect which relates to motor vehicle safety exists in certain model
2020-2021 Cougar Fifth Wheels and Travel Trailers. As a result, Keystone RV is conducting a safety recall. We
apologize for any inconvenience this action may cause you; however your safety and continued satisfaction are of the
utmost importance to us.
It has been decided that the vehicles in the recall population have an inverter that may have been
incorrectly wired and when in use, is allowing power to energize the shore power connection. When
the incorrectly wired inverter is turned on, 120VAC power will energize the shore power connection
leading to an increased risk of personal injury.
Keystone representatives have been in contact with the staff at your selling dealership regarding this
situation. The remedy is test the function of the inverter and rewire as needed. The service and parts
required for this corrective action will be provided at no charge to you.
If the inverter is turned on and any circuits other than the “Off The Grid Inverter Outlet” circuit is
powered on then turn off the inverter and have the system inspected by an authorized dealer. As
soon as possible, please make an appointment to have your RV serviced by your dealership. The
labor time to perform this correction is approximately 1 hour. Please ask your dealer if you wish to
know how much additional time will be needed to schedule and process your RV for this repair.
Your dealer is best equipped to obtain parts and provide service to ensure your RV is corrected as
promptly as possible. Please contact Keystone Customer service if your dealer is unable to assist or
if you take your RV to your dealer on the agreed service date, and the dealer does not remedy the
condition within a reasonable amount of time, or without charge to you. You may be eligible to
receive reimbursement if you paid to have the defect resolved prior to receiving this correspondence.
Keystone Customer Service is available toll-free at 1-866-425-4369.
If after contacting Keystone Customer Service you are still not satisfied we have done our best to remedy this situation,
you may also submit a written complaint to: Administrator, National Highway Traffic Safety Administration, 1200
New Jersey Avenue, SE, Washington, DC 20590. You may call the toll-free Vehicle Safety Hotline at 1-888-327-
4236 (TTY: 1-800-424-9153; or go to https://www.safercar.gov.) Federal regulations require that any vehicle lessor
receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Thank you for your attention and cooperation in this matter.
Sincerely,
KEYSTONE RV COMPANY
Rick Deisler
Vice President Service Operations
cc: National Highway Traffic Safety Administration (NHTSA)
Reason for
this recall
What we
will do
What we
need you to
do
If you have
questions
RECREATIONAL VEHICLE
SAFETY RECALL NOTICE
Safety Recall: 20V-670
Safety Advisory: 20-389
November 18, 2020
*************************************************************************************************************
PO Box 2000 – Goshen, IN 46527-2000
Phone: (574) 535-2100 – Fax: (574) 535-2199
www.keystonerv.com
SAFETY ADVISORY 20-389
«Dealer_name»
ATTN: Service Manager
«Street»
«Street_2»
«City», «State» «Zip»
«Country»
Dear «Dealer_name»,
Keystone RV Company has decided that a defect which relates to motor vehicle safety exists in certain model
2020-2021 Cougar Fifth Wheels and Travel Trailers. As a result, Keystone RV is conducting a safety recall.
It has been decided that the vehicles in the recall population have an inverter that may have been
incorrectly wired and when in use is allowing power to energize the shore power connection.
When the incorrectly wired inverter is turned on, 120VAC power will energize the shore power
connection leading to an increased risk of personal injury. The vehicles included in the recall are:
2020-2021 Cougar Fifth Wheels and Travel Trailers, 22RBSWE, 24SABWE, 25BHSWE, 26RBSWE,
27RESWE, 27SABWE, 29BHSWE, 29RLDWE, 29RLKWE, 29RLSWE, 30RKDWE, 31BHKWE,
32RDBWE, 24RDS, 25RES, 27SGS, 29MBS, 29RKS, 302RLS, 307RES, 30RLS, 315RLS, 316RLS, 32BHS,
353SRX, 364BHL, 366RDS, 367FLS, 368MBI, 361RLW
Serial Number Ranges: 2020 L2502429 – L2509218
LC503863 – LC509167
2021 M2500058 – M2505320
MC500000 – MC502509
Our records indicate unit(s) sold or in your present lot inventory fall within this range, which will require immediate
preventative action. Important: If some of the units are still in your inventory, Federal Law requires you to
complete the recall service on those units before retail delivery. The unit VIN(s) our records indicate are presently in
your inventory or have been sold are as follows:
«VIN1» «VIN2» «VIN3» «VIN4»
«VIN5» «VIN6» «VIN7» «VIN8»
«VIN9» «VIN10» «VIN11» «VIN12»
«VIN13» «VIN14» «VIN15» «VIN16»
«VIN17» «VIN18» «VIN19» «VIN20»
«VIN21» «VIN22» «VIN23» «VIN24»
«VIN25» «VIN26» «VIN27» «VIN28»
«VIN29» «VIN30» «VIN31» «VIN32»
«VIN33» «VIN34» «VIN35» «VIN36»
«VIN37» «VIN38» «VIN39» «VIN40»
«VIN41» «VIN42» «VIN43» «VIN44»
«VIN45» «VIN46» «VIN47» «VIN48»
«VIN49» «VIN50» «VIN51» «VIN52»
«VIN53» «VIN54» «VIN55» «VIN56»
«VIN57» «VIN58» «VIN59» «VIN60»
«VIN61» «VIN62» «VIN63» «VIN64»
«VIN65» «VIN66» «VIN67» «VIN68»
«VIN69» «VIN70» «VIN71» «VIN72»
«VIN73» «VIN74» «VIN75» «VIN76»
«VIN77» «VIN78» «VIN79» «VIN80»
«VIN81» «VIN82» «VIN83» «VIN84»
«VIN85» «VIN86» «VIN87»
— Serial numbers with ‘*’ have been retail sold —
Reason for
this recall
RECREATIONAL VEHICLE
SAFETY RECALL NOTICE
Safety Recall: US: 20V-670
CAN: 2020-526
Safety Advisory: 20-389
November 18, 2020
PO Box 2000 – Goshen, IN 46527-2000
Phone: (574) 535-2100 – Fax: (574) 535-2199
www.keystonerv.com
Claims for the units which have been serviced must be submitted. Claims submitted will be used by Keystone to
record recall service completions and provide dealer payments. Enclosed is a copy of the Safety Advisory #20-389,
which details how to remedy the situation and the proper reimbursement procedures.
We apologize for any inconvenience this situation may cause and greatly appreciate your cooperation. Should you
have any questions or concerns regarding this correspondence or the enclosed Safety Advisory, please feel free to
contact us.
Sincerely,
KEYSTONE RV COMPANY
Rick Deisler
Vice President Service Operations
cc. National Highway Traffic Safety Administration (NHTSA)
cc. Transport Canada
*************************************************************************************************************
SEOCONTENT-END
2 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| KEYSTONE | COUGAR | 2020-2021 |
14 Associated Documents
Remedy Instructions and TSB
RCRIT-20V670-2524.pdf 1294.978KB
Manufacturer Notices(to Dealers,etc)-20-389 dealer email 12-15-20
RCMN-20V670-9843.pdf 129.612KB
Recall Quarterly Report #1, 2020-4
RCLQRT-20V670-8023.PDF 211.135KB
Recall Quarterly Report #3, 2021-2
RCLQRT-20V670-7959.PDF 211.323KB
Recall Quarterly Report #2, 2021-1
RCLQRT-20V670-4945.PDF 211.235KB
Manufacturer Notices(to Dealers,etc)-20-389 dealer email 11-17-20
RCMN-20V670-5829.pdf 122.836KB
Miscellaneous Document- 20-389 tweet screenshot
RMISC-20V670-7511.pdf 15.554KB
Remedy Instructions and TSB
RCRIT-20V670-2758.pdf 1295.029KB
ISSUED Owner Notification Letter(Part 577)
RCONL-20V670-5515.pdf 93.979KB
Miscellaneous Document-20-389 Cougar Inverter Wiring – Web
RMISC-20V670-6529.pdf 53.558KB
Manufacturer Notices(to Dealers,etc)
Recall Acknowledgement
RCAK-20V670-2373.pdf 244.559KB
Defect Notice 573 Report
RCLRPT-20V670-3156.PDF 215.599KB
Recall Quarterly Report #4, 2021-3
RCLQRT-20V670-2182.PDF 211.433KB
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