Incorrect Wiring Missing Over-Current Protection – 2022 Forest River XLR Toy Hauler Recreational Vehicles

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October 22, 2021 NHTSA CAMPAIGN NUMBER: 21V829000

Incorrect Wiring/Missing Over-Current Protection

An electrical short increases the risk of a fire.

 

NHTSA Campaign Number: 21V829

Manufacturer Forest RivereBay, Inc.

Components ELECTRICAL SYSTEM, EQUIPMENT

Potential Number of Units Affected 3

 

Summary

Forest RivereBay, Inc. (Forest RivereBay) is recalling certain 2022 XLR Toy Hauler Recreational Vehicles. The vehicles were incorrectly wired, and they are missing 250AMP over-current protection, which could result in melted wires and an electrical short.

 

Remedy

Dealers will replace the gauge wire, and install a sub panel with the correct breaker, free of charge. Owner notification letters were mailed November 5, 2021. Owners may contact Forest RivereBay Customer Service at 1-574-642-0432. Forest RivereBay’s number for this recall is 79-1429.

 

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.

 


2022 Forest River XLR Toy Hauler
2022 Forest RivereBay XLR Toy Hauler

 


RECALL 21V829 REMEDY INSTRUCTIONS

Make(s): XLR BOOST
Model(s): XLT25LRLE-79
Model Year(s): 2022
Repair Code: RC-003-01-00-004115
Allotted Time: .75 HRS.
Inspection Code: N/A
Allotted Time: N/A
Concern:
An incorrect 12V and 110V gauge wire was installed during manufacturing for the inverter. The 12V is missing a breaker as it the 110V.
Photo(s) Required: YES
Prior Authorization Required: NO
Part(s) Kit Number: 791429
Part(s) Return: N/A

 

Disconnect the vehicles’ battery Positive and Negative, disconnect any House battery(s) Positive and Negative, if equipped with a generator ensure it is off and lastly, ensure the vehicle is disconnected from shore power.  Block any tires/wheels to prevent the vehicle from rolling. Failure to do so may result in electrocution, fire or other personal injury, property damage and/or death.

 

Parts Kit From XLR:

1 – 250AMP – 12V Breaker
1 – Red – 0/0 Wire with ends crimped/eyelets that is 18” long
1 – Red – 0/0 Wire with ends crimped/eyelets that is 30” long
1 – Black – 0/0 Wire with ends crimped/eyelets that is 48” long
1 – 15AMP – 110V Breaker
1 – 3’ Length of 12/2Ga. 110V Wire
1 – 110V Subpanel
2 – Strain Relief Subpanel Connectors for 110V Wire

 

REMEDY FOR THE 12V SIDE:

STEP 1: LOCATE THE 2 GAUGE 12V BLACK AND RED WIRE(S) THAT ARE ROUTED FROM THE INVERTER TO   THE BATTERY COMPARTMENT;

 

STEP 2: DISCONNECT FROM THE BATTERY AND FROM THE INVERTER, DISCARD OF THE 2 GAUGE BLACK   AND RED WIRES APPROPRIATELY;

 

STEP 3: IN THE PARTS KIT, LOCATE THE 0/0 BLACK WIRE, CONNECT TO THE 12V SIDE OF THE INVERTER AND   ROUTE TO THE NEGATIVE POST OF THE BATTERY (DO NOT HOOK UP);

 

STEP 4: IN THE PARTS KIT, LOCATE THE 0/0 RED WIRE, THERE WILL BE TWO, THE LONGEST RED WIRE WILL   HOOK TO THE INVERTER AND ROUTE CLOSE TO THE BATTERY COMPARTMENT (WITHIN 18”);

 

STEP 5: IN THE PARTS KIT, LOCATE THE 12V – 250AMP BREAKER AND LOCATE A SAFE PLACE WITHIN 18” OF   THE BATTERY TO MOUNT THE 250AMP BREAKER. CONNECT THE 0/0 RED WIRE TO THE 250AMP   BREAKER;

 

STEP 6: IN THE PARTS KIT, LOCATE THE SHORTER 0/0 RED WIRE, CONNECT IT TO THE OTHER POST ON THE  12V – 250AMP BREAKER, THEN ROUTE THE OTHER END OF THE RED WIRE TO THE BATTERY COMPARTMENT (DO NOT HOOK UP);

 

 

REMEDY FOR THE 110V SIDE:

STEP 1: DIRECTLY ABOVE THE INVERTER, INSTALL THE SUBPANEL TO THE WALL (FIG. 1);

 

STEP 2: INSTALL THE 15AMP BREAKER INTO THE SUBPANEL (FIG 1);

 

STEP 3: REMOVE THE CORRESPONDING BREAKER “KNOCK-OUT” FROM THE SUBPANEL’S COVER; Ø NOTE: IT IS EXTREMELY IMPORTANT THAT YOU ONLY TAKE OUT THE “KNOCK-OUT” THAT CORRESPONDS WITH THE BREAKER LOCATION. IN THE EVENT YOU MISTAKENLY REMOVE THE WRONG “KNOCK-OUT” YOU WILL BE REQUIRED TO PROCURE AN APPROVED SUBPANEL “KNOCK-OUT” PLUG AND INSTALL IT IN THE SUBPANEL!

 

STEP 4: LOCATE THE YELLOW 12 GAUGE 110V WIRE THAT IS WIRED INTO THE INVERTERS “OUTPUT SIDE”

AND DISCONNECT THIS WIRE FROM THE INVERTER (FIG. 2);

 

STEP 5: INSTALL A STRAIN RELIEF FROM THE PARTS KIT TO THE YELLOW 12GA. WIRE AND FEED THE WIRE   THROUGH A “KNOCK-OUT” ON THE SIDE OF THE SUBPANEL. ENSURE YOU LEAVE ENOUGH LENGTH OF WIRE TO CONNECT TO THE 15AMP BREAKER, GROUND BAR AND NEUTRAL BAR. THIS WILL NOW   “BE THE FEED SIDE WIRE (FIG. 3);

 

STEP 6: USE THE 3’ 12/2 YELLOW WIRE FROM THE PARTS KIT, INSTALL A STRAIN RELIEF ON ONE END. FEED   THE WIRE THROUGH A SEPARATE “KNOCK-OUT” ON THE SIDE OF THE SUBPANEL. ENSURE YOU LEAVE ENOUGH LENGTH OF WIRE TO CONNECT TO THE “HOT LUG”, GROUND BAR AND NEUTRAL   BAR. THIS WILL BE THE “LOAD SIDE WIRE (FIG. 1);

 

STEP 7: THE LOAD SIDE WIRE NOW NEEDS CONNECTED TO THE INVERTERS “OUTPUT SIDE”. ENSURE TO TRIM EXCESS WIRE AND ONLY STRIP A MINIMAL AMOUNT OF SHEATHING FROM THE BLACK AND   WHITE WIRE, ENOUGH TO PROPERLY ENGAGE WITH THE INVERTER TERMINAL (FIG. 1);

 

STEP 8: ENSURE ALL CONNECTIONS ARE SECURE. PLACE THE SUBPANEL COVER ON;

 

STEP 9: TURN THE 15AMP BREAKER IN THE SUBPANEL TO THE “OFF” POSITION;

 

TEST PROCEDURE:

STEP 1: CONNECT A FULLY CHARGED BATTERY TO THE VEHICLE. CONNECT ALL BATTERY CABLES, INCLUDING THE INVERTER 0/0 HOT AND GROUND;

 

STEP 2: PLUG THE VEHICLE IN TO 110V SHORE POWER;

 

STEP 3: INSPECT ALL CONNECTIONS WHERE WIRING WAS REPLACED. INSPECT INVERTER FOR PROPER   FUNCTIONALITY;

 

STEP 4: INSIDE THE VEHICLE, LOCATE THE RECEPTACLES THAT ARE POWERED BY THE INVERTER. PLUG A FAN OR SOMETHING SIMILAR INTO THESE RECEPTACLES – PLEASE NOTE: THE RECEPTACLES   SHOULD NOT WORK! AS THE 15AMP BREAKER IS “OFF” PER STEP 9 FROM THE 110V REMEDY   PROCEDURES;

 

STEP 5: LOCATE THE SUBPANEL AND TURN THE 15AMP BREAKER TO THE “ON” POSITION. TEST THE   RECEPTACLES AGAIN WITH A FAN OR SOMETHING SIMILAR. THE RECEPTACLES WILL BE IN WORKING   ORDER NOW.

 

STEP 6: CLAIM REPAIR CODE.

 


IMPORTANT SAFETY RECALL

NHTSA RECALL: 21V829
CANADA RECALL: N/A
FR ID: 79-1429

 

November 2021

 

This Notice applies to your vehicle VIN listed above.

 

Dear Forest RivereBay Customer:

 

This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This notice is also sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Forest RivereBay – Office of Corporate Compliance (“OCC”) has decided that a defect, which relates to the motor vehicle safety, exists in certain 2022 XLR Toy Hauler Recreational Vehicles. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.

 

WHAT IS THE DEFECT/NONCOMPLIANCE? 

The incorrect gauge wire was installed during manufacturing for the inverter as well as the incorrect breaker size.

 

EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.

The incorrect gauge wire could potently melt, causing a short, which could potentially lead to a fire, property damage and/or personal injury.

 

WHAT IS FOREST RIVEReBay AND OUR DEALERSHIPS GOING TO DO?

Forest RivereBay is notifying dealerships of the recall. You may have the recall corrected at any Forest RivereBay dealership. The correct wiring and proper breakers to protect the inverter will be installed. However, it is preferable if you have your selling dealership perform the remedy. Forest RivereBay completely covers your cost for the remedy; you will not receive any bill of sale for anything covered under the above recall number.

 

WHAT SHOULD YOU DO?

Please contact your dealer immediately and request a service appointment to schedule the free remedy to have the correct wiring and proper breakers to protect the inverter installed. The vehicle Owner is responsible for arranging to have the work completed.  Please state you have been notified by Forest RivereBay of having a recall in process for your vehicle and provide the recall number for the dealership.  It is also helpful to the dealership to have a copy of this letter when you take your vehicle in for the recall remedy.

 

You may also visit www.forestriverinc.com for dealer locations.

 

HOW LONG WILL THE REMEDY PROCESS TAKE?

The estimated time of repair is .75 hours.  However, the dealership may need to keep your vehicle or schedule an appointment with you for a later date to fit into their regular service schedule.

 

WHAT IF YOU HAVE PREVIOUSLY PAID FOR REPAIRS TO YOUR VEHICLE FOR THIS PARTICULAR CONDITION?

If you have already paid for a repair that is within the scope of this defect under recall, you still need to have this recall inspected and/or performed to ensure the correct parts and procedures were utilized.

Additionally, you may be eligible for a refund of previously paid repairs. Refunds will only be provided for within the scope of this defect under recall.

 

Please send the service invoice to the following address:

XLR
Forest RivereBay, Inc.
Attn: WARRANTY MANAGER
2421 Century Dr.
Goshen, IN 46528

 


Chronology :

On October 14, 2021, during a routine Corporate Quality Control inspection the improperly wired inverter was identified.

On October 15, 2021, the manufacturing plant contacted Forest Rivers’ Office of Corporate Compliance and an investigation was started.

On October 18, 2021, the vehicle scope was identified.

On October 22, 2021, Forest RivereBay’s Corporate recall committee voted to recall.

On October 28, 2021, The recall was amended to include the remedy.

 


1 Affected Product

Vehicle

MAKEMODELYEAR
FOREST RIVEReBayXLR TOYHAULER2022

 


10 Associated Documents

Recall Acknowledgement

RCAK-21V829-8037.pdf 645.976KB

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Defect Notice 573 Report

RCLRPT-21V829-3817.PDF 214.372KB

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Recall 573 Report – Amendment 1

RCLRPT-21V829-3781.PDF 215.042KB

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Remedy Instructions and TSB

RCRIT-21V829-0020.pdf 239.469KB

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Manufacturer Notices(to Dealers,etc)

RCMN-21V829-6717.pdf 218.145KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V829-3934.pdf 208.949KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V829-2331.PDF 211.138KB

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Recall Quarterly Report #2, 2022-1

RCLQRT-21V829-3343.PDF 211.235KB

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Recall Quarterly Report #3, 2022-2

RCLQRT-21V829-8114.PDF 211.319KB

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Recall Quarterly Report #4, 2022-3

RCLQRT-21V829-0387.PDF 211.422KB

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