2019-2020 Arcimoto FUV, & 2020 Deliverator HV Contactors & Battery Shutdown

March 18, 2021 NHTSA CAMPAIGN NUMBER: 21V191000

HV Contactors May Malfunction and Shutdown Battery

An unexpected battery shutdown can cause a loss of motive power, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V191

Manufacturer Arcimoto Inc

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 181

 

Summary

Arcimoto Inc (Arcimoto) is recalling certain 2019-2020 FUV, and 2020 Deliverator vehicles. The electronic drivers in some of the high voltage (HV) contactors may malfunction and overheat, which could cause the battery to shutdown.

 

Remedy

Arcimoto will notify owners, and an Arcimoto factory technician will replace the contactors and related components, free of charge. Arcimoto does not intend to send any dealer or distributor notifications, as it has neither dealers nor distributors at this time. The recall began March 29, 2021. Owners may contact Arcimoto customer service at 1-541-683-6293.

 

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.

 

Check for Arcimoto Recalls

 

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	Regulatory  Recall  Report		RRR0023
	Contactors  Excess  Resistance  May  Cause  Battery  Shutdown		Rev: 0
Author: PZ,  MM,  RS	PO: Dir  Regulatory	Appr: Dir  Regulatory	Date: 03/09/2021

 

1     SUMMARY

In  accordance  with  Part  573  of  Title  49  of  the  Code  of  Federal  Regulations,  Arcimoto  Inc.  hereby  reports  a  safety  issue  and  intends  to  recall  quantity  one-hundred  eighty-one  (181)  Arcimoto  Deliverator-1  and  FUVs  produced  between  September  19,  2019  and  December  31,  2020.  Due  to  an  improperly  implemented  remedy  in  both  Service  and  Production  using  the  new  003739  B-  Return  Harness  and  004955  Littelfuse,  the  subject  build  dates  and  VIN  range  was  increased.  The  electronic  drivers  in  some  HV  contactors  may  malfunction,  causing  these  contactors  to  have  a  higher  contact  resistance  than  intended,  potentially  resulting  in  overheating.  If  HV  contactors  overheat,  this  can  lead  to  either  a  blown  fuse  or  opening  of  the  contactors  by  the  BMS,  including  the  traction  contactor  opening,  both  of  which  will  lead  to  unexpected  battery  shutdown  and  immediate  loss  of  traction-power,  which  would  make  the  vehicle  more  difficult  to  control  and  increase  the  likelihood  of  a  crash.

Note:  Fields  left  blank  will  be  marked  “NR”  meaning  “Not  Reported”  in  public  view. 

 

2   NHTSA  MANUFACTURER  RECALL  PORTAL  FIELDS 

 

(c)1  IDENTIFICATION  OF  THE  MANUFACTURER,  IMPORTER,  DISTRIBUTOR,  OR  BRAND  NAME  OWNER

Manufacturer:	Arcimoto,  Inc.
Address:	2034  W.  2nd  Ave.,  Eugene  OR  97402
Contact:	Gerrit  Hurenkamp,  Director  of  Engineering

 

(c)2  VEHICLE  INFORMATION

Model  Year  Start:	Type:
2019	MOTORCYCLES
Model  Year  End:	Body  Style:
2020	OTHER
Make:	Powertrain:
Arcimoto	HYBRID  ELECTRIC
Model:	Descriptive  Information:
FUV,  Deliverator-1	Affects all one-hundred eighty-one
	MY2019  &  MY2020  vehicles  (fifty-seven MY2019  T-FUV,  one-hundred  eighteen MY2020  T-FUV,  six  MY2020  D-Deliverator-1)  produced  from 09/19/2019  through  to  12/31/2020.

 

Production  Dates:	Begin:  09/19/2019	End:  12/31/2020
VIN  Range(s):  (T  –  FUV,  tandem)	Begin: 7F7ATR312KER00000	End: 7F7ATR317KER00056
VIN  Range(s):  (D  –  Deliverator-1,  single)	Begin: 7F7ADR316LER00001	End: 7F7ADR315LER00006
VIN  Range(s):  (T  –  FUV,  tandem)	Begin: 7F7ATR312LER00001	End: 7F7ATR312LER00094
VIN  Range(s):  (T  –  FUV,  tandem)	Begin: 7F7ATR316LER00096	End: 7F7ATR31XLER00117
VIN  Range(s):  (T  –  FUV,  tandem)	Begin: 7F7ATR313LER00119	End: 7F7ATR31XLER00120

 

(c)3  TOTAL  NUMBER  POTENTIALLY  INVOLVED,  (c)4  ESTIMATED  PREVALENCE  OF  DEFECT

Number  potentially  involved:  181

Estimated  percentage  of  involved  with defect:  25%

 

(c)5  DEFECT  /  NONCOMPLIANCE  DESCRIPTION

For  this  Defect/Noncompliance:

Describe  the  defect  or  noncompliance:	Describe  the  safety  risk:
The  electronic  drivers  in  some  HV  contactors  may  malfunction,  causing  these  contactors  to  have  a  higher  contact  resistance  than  intended,  potentially  resulting  in  overheating.	If  HV  contactors  overheat,  this  can  lead  to  either  a  blown  fuse  or  opening  of  the  contactors  by  the  BMS,  including  the  traction  contactor  opening,  both  of  which  will  lead  to  unexpected  battery  shutdown  and  immediate  loss  of  traction-power,  which  would  make  the  vehicle  more difficult  to  control  and  increase  the  likelihood  of  a  crash.
If  a  noncompliance,  provide  the  applicable  FMVSS:	Identify  any  warning  which  can  precede  or  occur:
	None.
If          applicable,      provide           any      further  FMVSS  affected:
Describe  the  cause:
The  electronic  drivers  for  the  economizer  coil  in  some  HV  contactors  may  malfunction,  producing  out-of-tolerance  contact  resistance,  audible  ringing  noise,  and/or  misformed  economizer  coil  current  PWM,  causing  these  contactors  to  have  a  higher  contact  resistance  than  intended,  potentially  resulting  in  overheating.
This  Recall  affects  all  vehicles.

 

If  applicable,  identify  the  manufacturer  of  the  defective  or  noncompliant  component.  If  the  manufacturer  of  the  component  is  unknown,  provide  the  information  for  the  company  that  supplied  the  subject  component.

 

Component  Manufacturer:
Company  Information:	Company  Contact  Information:
Company  Name:	First  Name:
[Short  version] Sensata  Technologies  (formerly  Gigavac)   [Long  version] Sensata             Technologies  Inc.      (formerly  Gigavac)	Derek
Country:	Last  Name:
USA	Turner
Address  1:	Position:
529  Pleasant  Street	Engineering  Manager
Address  2:	Email:
Mail  Station  B-49	[email protected]
City:	Phone:
Attleboro	Office  805-684-8401  x150 Mobile  508-369-6288
State:
MA
Zip  /  Postal  Code:
02703

 

(c)6  CHRONOLOGY  OF  DEFECT  /  (c)7  NONCOMPLIANCE  DETERMINATION

Provide  the  chronology  of  events  leading  up  to  the  defect  decision  or  test  data  for  the  noncompliance  decision: 

[Short  version] 

On  5/19/20  a  customer  reported  that  while  driving  their  FUV  on  the  hwy,  it  suddenly  coasted  to  a  stop.  Arcimoto  immediately  examined  the  vehicle,  discovered  a  blown  fuse  &  evidence  of  overheating  involving  the  contactors.  All  fuses  were  immediately  tested,  but  determined  to  be  within  acceptable  limits  &  not  the  Root  Cause.  Analysis  then  focused  on  bus-bars,  fasteners,  &  conductive  graphite  grease,  which  were  all  tested,  but  they  were  determined  to  be  within  acceptable  limits  &  not  the  Root  Cause.  Resistance  testing  of  the  contactor  closest  to  the  blown  fuse  was  measured  to  be  1.5  times  the  acceptable  limit.  On  7/1  a  FUV  with  reduced  speed/acceleration  &  evidence  of  overheating  involving  a  contactor  measured  resistance  1.5  times  the  acceptable  limit.  On  7/2,  a  FUV  with  reduced  speed/acceleration  &  evidence  of  overheating  involving  a  contactor  measured  resistance  3.7  times  the  acceptable  limit.

On  7/3  Arcimoto  notified  NHTSA  of  SB-20-003  (20MC8034,  10176916),  which  sampled  vehicles  already  in  the  field  for  evidence  of  overheating;  this  method  revealed  3  vehicles that  each  had  1  contactor  that  exhibited  visual  evidence  of  overheating.  Upon  these  findings,  vehicle  sampling  under  SB-20-003  was  discontinued.

From  7/19  to  10/9,  more  complex  electronic  testing  on  contactors  was  developed  &  detected  new  contactors  with  excessive  contact  resistance,  audible  ringing  noise,  &/or misformed  economizer  coil  current  PWM,  each  of  which  could  result  in  overheating.  This  testing  demonstrated  the  Root  Cause  of  excessive  contact  resistance  within  the  contactor  led  to  overheating  &  validated  safety  concerns  about  the  vehicle  population.

Following  Arcimoto’s  process  starting  on  5/26  &  continuing  through  10/12,  research  data,  analysis,  &  developments  were  discussed  across  more  than  eight  meetings.  On  11/12,  the  Engineering  &  Q&RA  Depts  presented  findings  to  Arcimoto  executives,  who  decided  on  11/17  to  validate  these  findings  &  notify  NHTSA  of  a  Safety  Defect.

[Cont’d  in  Mfr  Comments  below]

 

[Long  version]

On  May  19,  2020  a  customer  complaint  reported  that  while  driving  at  speed  on  the highway,  an  Arcimoto  vehicle  suddenly  coasted  to  a  stop.  Arcimoto  immediately examined  the  vehicle,  which  revealed  a  blown  HV  fuse  and  evidence  of  overheating involving  the  HV  contactors.  All  HV  fuses  were  immediately  restricted  and  tested,  but consequently  determined  to  be  within  acceptable  limits  and  not  the  Root  Cause.  Analysis was  then  focused  on  bus-bars,  fasteners,  conductive  graphite  grease,  and  contactors, which  were  all  restricted  and  tested,  but  bus-bars,  fasteners,  and  conductive  graphite grease  were  determined  to  be  within  acceptable  limits  and  not  the  Root  Cause.  Resistance testing  of  the  contactor  closest  to  the  blown  fuse  was  measured  to  be  1.5  times  the acceptable  limit.  On  July  1,  2020  a  second  Arcimoto  vehicle  with  evidence  of  overheating involving  a  HV  contactor  was  identified  by  visual  inspection,  was  observed thermal-throttling  vehicle  speed,  and  similarly  measured  resistance  1.5  times  the acceptable  limit.  At  the  same  time,  a  third  Arcimoto  vehicle  with  evidence  of  overheating involving  a  HV  contactor  was  identified  by  an  overheated  battery  thermistor  closest  to  the contactor,  which  had  been  repeatedly  thermal-throttling  vehicle  speed,  and  measured resistance  3.7  times  the  acceptable  limit.

Arcimoto  immediately  notified  NHTSA  on  July  3,  2020  of  intent  to  implement  Arcimoto Service  Bulletin  SB-20-003,  recorded  by  NHTSA  as  Manufacturing  Communication 20MC8034  with  NHTSA  ID  10176916,  which  sampled  a  few  customer  and  company vehicles  already  in  the  field  and  looked  for  evidence  of  overheating.  On  the  first  thirteen vehicles  examined,  this  method  revealed  three  vehicles  that  each  had  at  least  one  HV contactor  that  exhibited  visual  evidence  of  overheating  but  no  functional  failures.  Upon these  findings,  vehicle  sampling  under  SB-20-003  was  discontinued.

Immediately  commencing  on  July  19  and  continuing  through  October  9,  extensive research  on  contactors  with  increasingly  complex  electronic  testing  was  established  and maintained,  discovering  new  out-of-the-box  contactors  with  out-of-tolerance  contact resistance,  audible  ringing  noise,  and/or  misformed  economizer  coil  current  PWM,  each of  which  could  result  in  overheating.  This  testing  finally  demonstrated  the  Root  Cause  to lie  within  the  HV  contactor,  validated  safety  concerns  about  excessive  contact  resistance leading  to  overheating  in  the  larger  vehicle  population,  and  confirmed  there  is  no  known advance  warning  to  the  vehicle  operator  of  these  failures.

Following  Arcimoto’s  process  starting  on  May  26,  2020  and  continuing  through  October  12,  2020,  Engineering  and  Q&RA  Departments  performed  research  and  analysis,  and  internal  Stakeholders  discussed  these  latest  data  and  developments  across  more  than  eight  research  meetings.  On  November  12,  2020,  the  Engineering  and  Q&RA  Departments  presented  all  documentation  and  findings  to  Arcimoto  executives,  who  subsequently  decided  on  November  17,  2020  to  validate  findings  of  a  Safety  issue  and  to  notify  NHTSA  of  a  Safety  Recall.

For  vehicles  already  remedied  under  this  recall  prior  to  early  February  2021,  as  well  as  those  built  after  this  original  defect  report  but  prior  to  early  February  2021,  the  newly  introduced  004955  Littelfuse  was  later  found  in  some  vehicles  to  be  damaged  during  the  installation  of  003739B  B-  Return  Harness.  Consequently,  (i)  the  subject  build  dates  and  VIN  range  was  increased,  and  (ii)  newly  introduced  parts  (003739B  B-  Return  Harness  and  004955  Littelfuse)  will  be  rescinded  and  replaced  (with  parts  003739C  B-  Return  Harness  and  002176  Mersen  fuse).

 

(c)8  IDENTIFY  THE  REMEDY

Describe  the  defect/noncompliance  remedy  program,  including  the  manufacturer’s  plan  for  reimbursement. 

Owners  will  be  notified  by  mail  and  instructed  to  contact  Arcimoto  to  schedule  a  service  appointment(s)  to  have  their  contactors  and  related  components  replaced.  There  will  be  no  charge  to  vehicle  owners  for  this  service.  To  the  best  of  our  knowledge,  no  owners  have  incurred  any  costs  resulting  from  this  defect.

 

Describe  what  distinguishes  the  remedy  component  from  the  recalled  component. 

Using  Arcimoto’s  new  advanced  electronic  testing,  all  HV  contactors  in  customers’  vehicles  will  be  extensively  inspected  and  tested,  and  any  identified  as  out-of-tolerance  will  be  replaced  with  contactors  tested  to  be  within  acceptable  limits.

All  HV  electronics  inside  the  compartment  for  the  traction-power  battery  will  be  replaced  with  redesigned  sub-assemblies,  including  (i)  the  bus-bars  attached  to  the  contactors  have  been  enlarged  for  increased  radiative  capacity,  (ii)  a  heat-sink  has  been  added  to  a  rear  bus-bar,  and  (iii)  a  redundant  second  fuse  for  the  traction-power  battery  has  been  eliminated.

Additionally,  due  to  an  improperly  implemented  remedy  in  both  Service  and  Production,  the  subject  build  dates  and  VIN  range  was  increased  to  reflect  these  additional  vehicles.  Specifically,  for  vehicles  built  after  this  original  defect  report  as  well  as  those  remedied  under  this  recall  prior  to  early  February  2021,  newly  introduced  parts  (003739B  B-  Return Harness  and  004955  Littelfuse)  will  be  rescinded  and  replaced  (with  parts  003739C  B-

Return  Harness  and  002176  Mersen  fuse).

 

Identify  and  describe  how  and  when  the  recall  condition  was  corrected  in  production. 

Using  Arcimoto’s  new  advanced  electronic  testing,  all  HV  contactors  received  from  Component  Manufacturer  will  be  extensively  inspected  and  tested,  to  ensure  all  product  is  within  acceptable  limits.

 

For  vehicles  in-process  or  already  produced  prior  to  November  18,  2020 :

All  HV  contactors  already  in  vehicles  will  be  re-tested,  and  any  identified  as  out-of-tolerance  will  be  replaced  with  contactors  tested  to  be  within  acceptable  limits.  All  HV  electronics  inside  the  compartment  for  the  traction-power  battery  will  be  reworked  with  redesigned  sub-assemblies,  including  (i)  the  bus-bars  attached  to  the  contactors  have  been  enlarged  for  increased  radiative  capacity,  (ii)  a  heat-sink  has  been  added  to  a  rear  bus-bar,  (iii)  a  redundant  second  fuse  has  been  eliminated,  and  (iv)  only  for  vehicles  already  remedied  under  this  recall  prior  to  early  February  2021,  newly  introduced  harness  and  fuse  will  be  rescinded  and  replaced  with  originally-designed  harness  and  fuse.

 

For  vehicles  produced  on  or  after  November  18,  2020 :

All  HV  electronics  inside  the  compartment  for  the  traction-power  battery  will  have  redesigned  sub-assemblies,  including  (i)  the  bus-bars  attached  to  the  contactors  have  been  enlarged  for  increased  radiative  capacity,  (ii)  a  heat-sink  has  been  added  to  a  rear  bus-bar,  (iii)  a  redundant  second  fuse  has  been  eliminated,  (iv)  only  for  vehicles  built  after  this  original  defect  report  but  prior  to  early  February  2021,  newly  introduced  harness  and  fuse  will  be  rescinded  and  replaced  with  originally-designed  harness  and  fuse,  and  (v)  the  rear  access-hole  of  the  compartment  for  the  traction-power  battery  has  been  enlarged.

 

Describe the recall schedule for  notifications:	Planned  Dealer  Notification  Begin  Date:
Arcimoto does not intend to send any dealer or distributor notifications, as it has neither dealers nor distributors at this time.	N/A
	Planned  Dealer  Notification  End  Date:
	N/A
	Planned  Owner  Notification  Begin  Date:
	03/22/2021

 

IDENTIFY  THE  RECALL  SCHEDULE

	Planned  Owner  Notification  End  Date:
	04/09/2021
Manufacturer’s identification code for this recall (if  applicable):

 

Please  be  reminded  that  owner  notification  letters  must  be  mailed  no  more  than  60  days  from  submission  of  this  report.

 

MANUFACTURER  COMMENTS  TO  NHTSA  STAFF

Arcimoto  does  not  intend  to  send  any  dealer  or  distributor  notifications,  as  it  has  neither  dealers  nor  distributors  at  this  time.

 

[Continuation  of  Chronology  of  Events:]

For  vehicles  already  remedied  under  this  recall  prior  to  early  February  2021,  as  well  as  those  built  after  this  original  defect  report  but  prior  to  early  February  2021,  the  newly  introduced  004955  Littelfuse  was  later  found  in  some  vehicles  to  be  damaged  during  the  installation  of  003739B  B-  Return  Harness.  Consequently,  (i)  the  subject  build  dates  and  VIN  range  was  increased,  and  (ii)  newly  introduced  parts  (003739B  B-  Return  Harness  and  004955  Littelfuse)  will  be  rescinded  and  replaced  (with  parts  003739C  B-  Return  Harness  and  002176  Mersen  fuse).

 

DOCUMENT  UPLOAD

1.1 (c)10  A  representative  copy  of  all  notices, bulletins,   and  other  communications  that  relate  directly  to  the  defect  or  noncompliance  and  are  sent  to  more  than  one  manufacturer,  distributor,  dealer  or  purchaser.  These  copies  shall  be  submitted  to  NHTSA’s  Recall  Management  Division  (NVS-215)

 

3     REVISION  HISTORY

Function	Role	Name	Signature	Date
Author	Dir  Regulatory	Pete  Z	<insert  name>	03/09/2021
Author	RA-RCP	Matt  M	<insert  name>	03/09/2021
Author	RA-RCA	Raymond  S	<insert  name>	03/09/2021
Author	Dir  Engineering	Gerrit  H	<insert  name>	03/09/2021
PO	Dir  Regulatory	Pete  Z	<insert  name>	03/09/2021
Approver	Dir  Regulatory	Pete  Z	<insert  name>	03/09/2021

 

Revision		Reason  for  change; Summary  of  change  from  prior  Revision
#	Date  Issued
0	11/18/2020	Initial  Issue Internal  Outline  of  Defect  and  Noncompliance  Report  Format  pursuant  to §573.6.  (Incorrect  online  portal  submission  resulted  in  original  submission  & Amendment  1  submission  using  this  same  R0.)
1	11/19/2020	Clarification Added  details.  Equivalent  to  Amendment  2.
2	03/09/2021	Corrections Changed  remedy  descriptions  per  to-date  PCM  meeting  agreements  & ECO-401.  Equivalent  for  new  recall  campaign.

 

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	Regulatory  Recall  Remedy  Method-Sheet		RRM0015
	21V191  Contactors  Excess  Resistance  May  Cause  Battery  Shutdown		Rev: 0
Author: LC,MM,PZ	PO: Dir  GRC	Appr: Dir  GRC	Date: 04/12/2021

 

1 PURPOSE

Safety  Recall  Remedy  Instructions:  Contactors

 

2 AFFECTED VEHICLES

Model  Year	Model	VIN  Range  (last  8  digits)
2019	FUV  Evergreen	KER00000  –  KER00056
2020	FUV  Evergreen	LER00001  –  LER00007
2020	FUV  Evergreen	LER00009  –  LER00091
2020	FUV  Evergreen	LER00096  –  LER00096

 

3 BACKGROUND

The  electronic  drivers  in  some  HV  contactors  may  malfunction,  causing  these  contactors  to  have  a  higher  contact  resistance  than  intended,  potentially  resulting  in  overheating.  If  HV  contactors  overheat,  this  can  lead  to  either  a  blown  fuse  or  opening  of  the  contactors  by  the  BMS,  including  the  traction  contactor  opening,  both  of  which  will  lead  to  unexpected  battery  shutdown  and  immediate  loss  of  traction-power,  which  would  make  the  vehicle  more  difficult  to  control  and  increase  the  likelihood  of  a  crash.

 

4 OWNER NOTIFICATION 

Owners  of  affected  vehicles  will  be  sent  a  notification  of  this  campaign.

 

5 CORRECTIVE ACTION 

A  trained  Arcimoto  Service  Technician  will  remedy  the  defective  parts  by  replacing  the  HV  contactors.

 

6 PARTS INFORMATION

Panel  –  Left  Lower  Dash  (002982)

Panel  –  Right  Lower  Dash  (002983)

Handlebar  Assy  (002109)

Panel  –  Left  Dash  Collar  (002970)

Panel  –  Right  Dash  Collar  (002971)

Display  Assy  (004612)

Dash  Center  Panel  Assy  (004975)

Seat  Base  (004140)

Seat  Back  (004141)

Cargo  Box  Assy  (003158)

Rear  Left  Side  Panel  (002998)

Rear  Right  Side  Panel  (002999)

Rear  Center  Panel  Assy  (003000)

Rear  Wheel  Liner  Panel  (003001)

Chassis  Lid  (003144)

Backbone  Assembly  (003105)

B-Return  Harness  (003739)

Battery  Electronics  Assy  (003524)

Harness  –  BMS  (002309)

Busbar  –  Mid-Pack  (003024)

Battery  Bay  Assy  (003196)

Battery  Electronics  Assy  V2  (004947)

Busbar  –  Contactor  to  Battery (004910)

Backbone  Assembly  (003105)

Rear  Large  Access  Plate  (004906)

Busbar  –  Contactor  to  Battery (004910)

B-Return  Harness  V2  (004956)

Busbar  Heatsink  (004950)

FUSE,  400A,  300V  (004955)

 

Note :  The  first  ten  vehicles  serviced  for  this  recall  will  use  (new)  Battery  Electronics  Assy  V2  ( 004947 )  parts.  After  that,  all  vehicles  serviced  for  this  recall  will  use  (refurbished)  “004947-R”  Battery  Electronics  Assy  V2  parts.

 

7 RELATED DOCUMENTS  AND  RESOURCES 

• Battery Electronics  Assy  V2  (004947)
• Backbone Assembly  (003105)

 

8 SAFETY REQUIREMENTS 

8.1 Required Training

Arc-Flash  Safety  Training

8.2 Required Protective  Gear

Full  PPE,  category  2,  8  Cal/cm2  (Suit,  Gloves  and  Helmet)  for  use  by  the  technician  working  directly  on  the  vehicle

6-foot  non-conductive  pole  or  rod,  for  use  by  Spotter  if  necessary

 

9 SERVICE PROCEDURE 

 

9.1 Remove the  Left  Lower  Dash  Panel  ( 002982)  and  the  Right  Lower  Dash  Panel  (002983).

 

9.2 Remove HV  Power  From  the  FUV:

 

9.2.1 Press the  red  button  on  the  12V  Circuit  Breaker to   flip  the  yellow  RESET  lever  down  to  the  OFF    The  12V  Circuit  Breaker  is  accessed  via  the  right-side  access  port.

 

9.2.2 On each  of  the  (RED  and  YELLOW) Power   Output  Connectors,  press the   locking  tab  down,  and  gently  pull  to  unplug  the  Power  Output    The  Power  Output  Connectors  are  accessed  via  the  left-side  service  port.

 

9.3 Remove the  Handlebar  Assy  (002109).

 

9.4 Remove the  Left  Dash  Collar  Panel  ( 002970 )  and  the  Right  Dash  Collar  Panel  (002971).

 

9.5 Remove the  Display  Assy  (004612).

 

9.6 Remove the  Center  Dash  Panel  Assy  ( 004975 ).

 

9.7 Remove the  Front  and  Rear  Seat  Bases  ( 004140 ).

 

9.8 Remove the  Front  Seat  Back  (004141).

 

9.9 Remove the  Cargo  Box  Assy  ( 003158 ),  if equipped.

 

9.10 Remove the  Rear  Left  Side  Panel  (002998 )  and  the  Rear  Right  Side  Panel  ( 002999 ).

 

9.11 Remove the  Rear  Center  Panel  Assy  (003000).

 

9.12 Remove the  Rear  Wheel  Liner  Panel  ( 003001 ).

 

9.13 Safely elevate  the  front  of  the  vehicle  and  set  on  jack stands.

 

9.14 Disconnect the  three  connectors  on  top  of  the  Battery  Electronics  Assy  (003524):

 

9.14.1 Disconnect the  orange  2-pin  connector  (HV  Accessory  Bulkhead  Connector  Harness  ( 003361 )).

 

9.14.2 Disconnect the  blue  18-pin  connector  (Backbone  Harness  ( 003343 )).

 

9.14.3 Disconnect the  two-position  Powerlok  300  Connector  Assy  (003360     ).

 

9.15 Remove the  22  hex  flange  bolts  (M6-1.0  X  12) that   secure  the  Chassis  Lid  to  the  Backbone     Do  not  remove  the  Chassis  Lid  until  Arc-Protection  is  deployed  (see  16). 

 

9.16 Remove the  eight  socket  head  cap  screws  (SHCS, M5-0.8   X  10  ZN)  and washers   (M5)  that  secure  the  BatteryElectronics  Assy  to  the  Chassis Lid.

 

9.17 At this    the  technician  working  on the   vehicle  must  put on   full  Arc-Protection  gear  (PPE,  category  2,  8Cal/cm2  Suit,  Gloves  and  Helmet)  before  proceeding. 

 

9.18 Position the  Spotter,  equipped  with  a 6- foot  non-conductive  pole  or  rod,  approximately  six  feet  away  from  the    The  Spotter  must  be  positioned  such  that  they  can  clearly  observe  the  technician  and  intervene  in  case  of  an  emergency  before  proceeding. 

 

9.19 Remove the  Chassis  Lid  ( 003144 ).

 

9.20 Remove the  two  4-40  X  1/8″  security  screws, then   disconnect  the  BMS  Connector  on  the  Front  Battery

 

9.21 Remove the  two  4-40  X  1/8″  security  screws, then   disconnect  the  BMS  Connector  on  the  Rear  Battery

 

9.22 Remove the  Mid-Pack  Busbar  ( 003024 )  which connects   the  Front and   Rear  Battery  Modules  (located  in  the  center  of  the  Battery  Bay):

 

9.22.1 Remove the  black  plastic  safety  cap  from  the rear   (-)  terminal  on the   Front  Battery Module.

 

9.22.2 Remove the  red  plastic  safety  cap  from  the front   (+)  terminal  on the   Rear  Battery Module.

 

9.22.3 Remove the  eight  socket  head  cap  screws  (SHCS, M4-0.7   X  16)  and  washers  (4.3  ID/  9  OD  /  0  thick,  BellevilleSpring),  that  secure  the  Mid-Pack  Busbar  ( 003024 )  to  the  Front  and  Rear  Battery  Modules,  and  remove  the  Mid-Pack  Busbar.

 

9.22.4 Replace the  Safety Caps.

 

9.23 Disconnect the  BMS  Harness  ( 002309 )  from  the  Battery  Electronics

 

9.24 Remove the BMS Harness and set it aside.

 

9.25 Disconnect the Mid-Pack Busbar ( 003024 ) that connects the Front Battery Module to the Battery Electronics Assy:

 

9.25.1 Remove the red plastic safety cap from the front (+) terminal on the Front Battery Module.

 

9.25.2 Remove the four socket head cap screws (SHCS, M4-0.7 X 16) and washers (4.3 ID/ 9
OD / 1.0 thick, BellevilleSpring) that secure the Mid-Pack Busbar ( 003024 ) to the positive terminal on the Front Battery Module.

 

9.25.3 Replace the Safety Cap.

 

9.26 Unclip the four cable ties that secure the B-Return Harness to the Front and Rear Battery Modules.

 

9.27 Disconnect the B-Return Harness ( 003739 ) from the Battery Electronics Assy:

 

9.27.1 Remove the four screws (SHCS, M4-0.7 X 16) and washers (4.3 ID/ 9 OD / 1.0 thick, Belleville Spring) that secure the B-Cable to Battery Electronics Busbar ( 003787 ) to the front-end terminal on the B-Return Harness.

 

9.27.2 Move the B-Return Harness away from the Battery Electronics Assy.

 

9.28 Remove the FCG Connector on the Backbone Harness ( 003343 ) from the Quick Connect Tab on the front left of the Battery Bay.

 

9.29 Pull the Backbone Harness and the BMS Harness up and out of the Battery Bay, to provide slack to allow removal of the Battery Electronics Assy.

 

9.30 From beneath the vehicle, remove the six hex flange bolts (M6-1.0 X 12) that secure the Battery Electronics Assy (0 03524 ) to the Battery Bay Assy (0 03196 ).

 

9.31 Gently lift the Battery Electronics Assy out of the Battery Bay Assy, taking care not to damage the wiring and connectors.

 

9.32 Remove the Backbone Harness (0 03343 ) from the Battery Electronics Assy:

 

9.32.1 Slide the red plastic Slide-Clip off of the blue BFJ connector.

 

9.32.2 Push the blue BFJ connector through the connection plate, and remove the Backbone Harness.

 

9.32.3 Move the Backbone Harness BFJ out of the way, but leave it installed in the Battery Bay because it will be used in the new Battery Electronics Assy V2 (see step 9.35).

 

9.33 Disconnect all connectors from the Battery Electronics Assy, and set the Battery Electronics Assy aside.

 

9.34 Remove the Backbone Harness from the (new) Battery Electronics Assy V2 ( 004947 ):

 

9.34.1 Slide the red plastic Slide-Clip off of the blue BFJ connector.

 

9.34.2 Push the blue BFJ connector down and through the connection plate, and remove the Backbone Harness.

 

9.35 Install the Backbone Harness that was removed from the original Battery Electronics Assy (see step 28) into the new Battery Electronics Assy V2:

 

9.35.1 Insert the blue BFJ connector on the Backbone Harness from underneath the connection plate on the Battery Electronics Assy V2.

 

9.35.2 Slide the red plastic Slide-Clip onto the BFJ connector to secure it to the connection plate.

 

9.36 Install a new Battery Electronics Assy V2 ( 004947 ):

Note: The first ten vehicles serviced for this recall will use (new) Battery Electronics Assy V2 ( 004947 ) parts. After that, all vehicles serviced for this recall will use (refurbished) “004947-R” Battery Electronics Assy V2 parts.

 

9.36.1 Reconnect all connectors to the Battery Electronics Assy V2.

 

9.36.2 Insert the Battery Electronics Assy V2 into position at the front of the Battery Bay Assy. Ensure that the straight horizontal Busbar ( 003024 ) extending from the Battery Electronics Assy V2 is properly aligned with the front (+) terminal on the Front Battery
Module.

 

9.36.3 Use six hex flange bolts (M6-1.0 X 12) to secure the Battery Electronics Assy V2 to the Battery Bay Assy. Use new fasteners and torque all bolts to 8 FT-LBS, and apply torque seal.

 

9.36.4 Attach the Contactor to Battery Busbar ( 004910 ) to the front (+) terminal on the Front Battery Module. Use new fasteners (four screws (SHCS, M4-0.7 X 16) and washers (4.3 ID/ 9 OD / 1.0 thick, Belleville Spring). Torque all screws to 25 IN-LBS, and apply torque seal.

 

9.37 Remove the busbar that connects the Rear Battery Module to the Rear (Negative Terminal) Contactor Assy (0 03742 ):

Note: This busbar is an assembly of three component busbars ( 003729 , 003730 and 003024 ). Leave this busbar assembly intact, and remove it as one piece.

 

9.37.1 Remove the black plastic safety cap from the rear (-) terminal on the Rear Battery Module.

 

9.37.2 Remove the four socket head cap screws (SHCS, M4-0.7 X 16) and washers (4.3 ID/ 9 OD / 1.0 thick, Belleville Spring) that secure the busbar to the negative terminal on the Rear Battery Module.

 

9.37.3 Remove the bolt that secures the busbar to the Rear Contactor Assy.

 

9.37.4 Remove the busbar and set aside.

 

9.38 Remove the B-Return Harness ( 003739 ):

 

9.38.1 Remove the bolt that secures the B-Return Harness to the Rear Contactor Assy.

 

9.38.2 Pull the B-Return Harness (with Busbar – Rear Contactor to Fuse (003731) and 400A Fuse (0 04955 ) attached) out of the Battery Bay, and set aside.

 

9.39 Remove the Rear (Negative Terminal) Contactor Assy (0 03742 ):

 

9.39.1 Remove both socket head cap screws (SHCS, M5-0.8 X 20) that secure the Rear Contactor Assy to the Battery Bay.

 

9.39.2 Pull the Rear Contactor Assy out of the Battery Bay and set aside.

 

9.40 Install the new B-Return Harness V2 ( 004956 ), pre-assembled with Heatsink Busbar ( 004950 ) and 400A Fuse (0 04955 ):

Note: Before installing the new B-Return Harness V2 ( 004956 ), visually check the crimp orientation of the rear 5/16” cable-lug terminal. Ensure that the crimp orientation of the rear cable-lug terminal is perpendicular (not parallel) to the surface of the cable-lug terminal.

If the crimp orientation on the new B-Return Harness V2 ( 004956 ) is incorrect, the cable must be refurbished before it can be used.

 

9.40.1 Route the front end of the B-Return Harness V2 through the Access Port at the rear of the Backbone Assy, to the Battery Electronics Assy V2 (at the front)

 

9.40.2 Attach the front connector of the B-Return Harness V2 to the B-Cable to Battery Electronics Busbar ( 003787 ) extending from the Battery Electronics Assy V2. Use new fasteners (four socket head cap screws (SHCS, M4-0.7 X16) and washers (4.3 ID/ 9 OD / 1.0 thick, Belleville Spring). Torque all screws to 25 IN-LBS, and apply torque seal.

 

9.40.3 Install four Cable Ties ( 002259 ) at the four Cable Tie Mounts ( 003757 ) to secure the B-Return Harness to the Front and Rear Battery Modules.

 

9.41 Install the new Rear (Negative Terminal) Contactor Assy (0 03742 ):

 

9.41.1 Insert the new Rear Contactor Assy into position through the Access Port at the rear of the Backbone Assy. The raised notch on the top surface of the Contactor should face to the rear.

 

9.41.2 Use two socket head cap screws (SHCS, M5-0.8 X 20) to secure the new Rear Contactor Assy to the Battery Bay.

Use new fasteners and torque both screws to 25-30 IN-LBS, and apply torque seal.

 

9.42 Install the busbar that connects the Rear Contactor Assy to the Rear Battery Module:

 

9.42.1 Attach the top of the busbar to the negative terminal on the Rear Battery Module. Use new fasteners (four screws (SHCS, M4-0.7 X 16) and washers (4.3 ID/ 9 OD / 1.0 thick, Belleville Spring). Torque all screws to 25 IN-LBS, and apply torque seal.

 

9.42.2 Use the nut supplied with the contactor, and washer (8.4 ID/ 18 OD / 2.0 thick, Belleville Spring) to secure the bottom of the busbar to the left-side post on the Rear Contactor Assy. Torque nut to 7.5 FT-LBS, and apply torque seal.

 

9.42.3 Replace the black plastic safety cap on the rear (-) terminal on the Rear Battery Module.

 

9.43 Attach the Heatsink Busbar (attached to the B-Return Harness V2 ( 004956 )) to the Rear Contactor Assy:

 

9.43.1 Position the Heatsink so that the fins face to the front.

 

9.43.2 Use the nut supplied with the contactor, and washer (8.4 ID/ 18 OD / 2.0 thick, Belleville Spring) to secure the bottom of the busbar to the right-side post on the Rear Contactor Assy. Torque nut to 7.5 FT-LBS, and apply torque seal.

 

9.44 Replace the Rear Large Access Plate (004906), and secure it with silicone bead and four hex flange bolts (M6-1.0 X12). Torque bolts to 8 FT-LBS, and then apply torque seal.

 

9.45 Tuck the harnesses in the Battery Bay between the left side of the Battery Modules and the wall of the Battery Bay.

 

9.46 Re-install the Mid-Pack Busbar (003024). Use new fasteners (four socket head cap screws (SHCS, M4-0.7 X 16) and washers (4.3 ID/ 9 OD / 1.0 thick, Belleville Spring). Torque all screws to 25 IN-LBS, and apply torque seal.

 

9.47 Re-connect the BMS Harness (002309) in the following order:

 

9.47.1 First, connect the BMS Connector on the Rear Battery Module, and secure the connector with two 4-40 X 1/8″security screws.

 

9.47.2 Next, connect the BMS Connector on the Front Battery Module, and secure the connector with two 4-40 X 1/8″security screws.

 

9.47.3 Re-connect the front end connectors in the Battery Electronics Assy.

 

9.48 Reinstall the Chassis Lid (003144) on the Backbone Assy (003105). Use 22 hex flange bolts (M6-1.0 X 12). Torque all bolts to 8 FT-LBS, and apply torque seal.

 

9.49 Reinstall the Rear Wheel Liner Panel (003001).

 

9.50 Reinstall the Rear Center Panel Assy (003000).

 

9.51 Reinstall the Rear Left Side Panel (002998) and the Rear Right Side Panel (002999).

 

9.52 Reinstall the Cargo Box Assy (003158), if equipped.

 

9.53 Reinstall the Front Seat Back (004141).

 

9.54 Reinstall the Front and Rear Seat Bases (004140).

 

9.55 Reinstall the Center Dash Panel Assy (004975).

 

9.56 Reinstall the Display Assy (004612).

 

9.57 Reinstall the Left Dash Collar Panel (002970) and the Right Dash Collar Panel (002971).

 

9.58 Reinstall the Handlebar Assy (002109).

 

9.59 Restore HV power to the FUV:

 

9.60 Reinstall the Left Lower Dash Panel (002982) and the Right Lower Dash Panel (002983).

 

9.61 Safely lower the FUV.

 

10 REVISION HISTORY 

Function	Role	Name	Signature	Date
Author	Tech’l  Content  Writer	Larry  C	<insert  name>	04/12/2021
Author	GRC  Paralegal	Matt  M	<insert  name>	04/12/2021
Author	Dir  GRC	Pete  Z	<insert  name>	04/12/2021
PO	Dir  GRC	Pete  Z	<insert  name>	04/12/2021
Approver	Dir  GRC	Pete  Z	<insert  name>	04/12/2021
Checker	RCP	Matt  M	<insert  name>	04/12/2021

 

Revision		Reason for change; Summary of change from prior Revision
#	Date  Issued
0	04/12/2021	Initial Issue Safety Recall Remedy Instructions: Contactors NHTSA recall ID has changed from 20V717 to 21V191

 

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3 Affected Products

Vehicles

MAKE	MODEL	YEAR
ARCIMOTO	DELIVERATOR	2020
ARCIMOTO	FUV	2019-2020

 

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11 Associated Documents

Part 577 Owner Notification Envelope

RONE-21V191-1853.pdf 73.529KB

 

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Recall Acknowledgement

RCAK-21V191-6996.pdf 645.578KB

 

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Miscellaneous Document – Regulatory Recall Report re Contactors Excess Resistance May Cause Battery Shutdown

RMISC-21V191-1087.pdf 282.385KB

 

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Recall 573 Report

RCLRPT-21V191-3728.PDF 216.676KB

 

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Defect Notice 573 Report

RCLRPT-21V191-7001.PDF 216.676KB

 

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Recall 573 Report

RCLRPT-21V191-1101.PDF 219.349KB

 

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Remedy Instructions and TSB

RCRIT-21V191-5019.pdf 314.733KB

 

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Recall Quarterly Report #2, 2021-2

RCLQRT-21V191-1387.PDF 211.232KB

 

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Recall Quarterly Report #1, 2021-1

RCLQRT-21V191-4306.PDF 211.128KB

 

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Recall Quarterly Report #4, 2021-4

RCLQRT-21V191-1581.PDF 211.419KB

 

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Recall Quarterly Report #3, 2021-3

RCLQRT-21V191-6410.PDF 211.315KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V191&docType=RCL

 

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