22E001 – Wire Harness Built Incorrectly – Volta Adaptor Harness

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-001
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Volta Power Systems LLC
Submission Date : APR 05, 2022
NHTSA Recall No. : 22E-001
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Volta Power Systems LLC
Address : 12550 Superior Ct
Holland MI 49424
Company phone : 226-4222
Population :
Number of potentially involved : 646
Estimated percentage with defect : 100 %
Equipment Information :
Brand / Trade 1 : Volta Power Systems
Model : adaptor harness
Part No. : 100001146
Size : 8 inchs
Function : communication
Descriptive Information : – This references an existing case 21V-793
-The population started at the date parts where first received from sub supplier.
– The previous parts built at Volta had a fuse and a diode in opposite positions on
a circuit.
– Winnebago Travato 2021, Winnebago Boldt 2021, and Storyteller Overland
Vans 2021
Production Dates : JUN 18, 2021 – OCT 01, 2021
Description of Defect :
Description of the Defect : Per the request of NHTSA representative Choon Lee, Volta submits this report:
In the case that power connections are not properly seated severe voltage
spike caused by intermittent connections could damage the filtering diode in
the alternator control harness (10001447) resulting in the possibility of a
shorted wire, on the same circuit the order of the fuse and diode were reversed.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In the case that the diode is broken in a closed condition, the sense wire
could be shorted to ground resulting in an overheated wire or broken wire.
Description of the Cause : The identified cause of the diode failure was excessive overvoltage spikes.
When the diode failed, it failed closed and with the diode and fuse being
reversed the wire continued to heat up instead of breaking the fuse.
Part 573 Safety Recall Report 22E-001 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Identification of Any Warning
that can Occur :
Load dump faults within the BMS of the battery system.
Involved Components :
Component Name : Adapter Harness
Component Description : Wire harness designed by Volta that controls communication to an alternator
controller
Component Part Number : 100001146
Supplier Identification :
Component Manufacturer
Name : Tack Electronics
Address : 5030 Kraft Ave
Grand Rapids Michigan 49512
Country : United States
Chronology :
Winnebago contacted Volta on Oct 8, 2021 regarding a vehicle that experienced a thermal event. Winnebago
asked Volta to review the vehicle and support the investigation. On Oct 11, 2021 a team from Volta was on site
at Winnebago for three days to review the vehicles that had experienced the failure. Winnebago provided
evidence that they believed the failure was due to a diode within the Volta designed alternator control harness.
Volta then began looking for root cause of how the diode was damaged and/or failed. Volta verified the
certification of the parts, reviewed the manufacturing processes at Volta’s suppliers, reviewed engineering
drawings, and inspected vehicles for installation errors. On Oct 12 we discovered that the main power
connections, and ground bus bars installed by Winnebago on all vehicles present with the failure were finger
tight and did not have the required torque marks signifying that the terminals where properly tightened.
During the investigation of the drawings we also discovered that the fuse and diode order was reversed on the
Volta harness drawings. The subject Adapter Harness was also part of a non-safety related review in
connection with the Storyteller installations which commenced on or about Oct 13 and resulted in a
replacement program being instituted by Storyteller for those vehicles on or about Oct 14.
Part 573 Safety Recall Report 22E-001 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Volta is cooperating with Winnebago’s on-going recall and, further, is
cooperating with Storyteller Overland’s replacement program. Volta has
provided the units at no cost and is supporting installation costs.
How Remedy Component Differs
from Recalled Component :
New part number with order of fuse and diode reversed.
Identify How/When Recall Condition
was Corrected in Production :
A revised drawing with the reversed order of the fuse and diode was
provided to Volta supply chain and replacement parts where built. Volta
conducted a retraining at Winnebago on the importance and methods of
torqueing power terminals.
Recall Schedule :
Description of Recall Schedule : Winnebago recall performed by Winnebago. All parts requested have
been supplied to Winnebago for their recall started Dec 3, 2021. Parts
were also supplied to Storyteller Overland. As of January 7, 2022, Volta
had sold 288 suspect units to Storyteller of which 61 were replaced
within Storyteller’s control and of the remaining 227 parts, 217
replacement parts have been shipped (and 191 of the original affected
parts returned after replacement) in response to requests under the
Storyteller replacement program. The owners of ten (10) vehicles are
believed to have not yet responded to the Storyteller replacement
program, attempts to contact continue.
Volta notified Storyteller Overland of the condition with Winnebago on
10/14/2021. As stated above, harness replacement campaign, with
Storyteller Overland was already underway for the harness in relation to
continuous improvement activities.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : Storyteller Overland
Address : 516 35th St N. Suite A
Birmingham AL 35222
Country : US
Company Phone : 8889997442
Part 573 Safety Recall Report 22E-001 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : Winnebago Industries
Address : 605 Crystal Lake Rd
Forest City IA 50436-0152
Country : US
Company Phone : 6415856385
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-001
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Volta Power Systems LLC
Submission Date : APR 05, 2022
NHTSA Recall No. : 22E-001
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Volta Power Systems LLC
Address : 12550 Superior Ct
Holland MI 49424
Company phone : 226-4222
Population :
Number of potentially involved : 646
Estimated percentage with defect : 100 %
Equipment Information :
Brand / Trade 1 : Volta Power Systems
Model : adaptor harness
Part No. : 100001146
Size : 8 inchs
Function : communication
Descriptive Information : – This references an existing case 21V-793
-The population started at the date parts where first received from sub supplier.
– The previous parts built at Volta had a fuse and a diode in opposite positions on
a circuit.
– Winnebago Travato 2021, Winnebago Boldt 2021, and Storyteller Overland
Vans 2021
Production Dates : JUN 18, 2021 – OCT 01, 2021
Description of Defect :
Description of the Defect : Per the request of NHTSA representative Choon Lee, Volta submits this report:
In the case that power connections are not properly seated severe voltage
spike caused by intermittent connections could damage the filtering diode in
the alternator control harness (10001447) resulting in the possibility of a
shorted wire, on the same circuit the order of the fuse and diode were reversed.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In the case that the diode is broken in a closed condition, the sense wire
could be shorted to ground resulting in an overheated wire or broken wire.
Description of the Cause : The identified cause of the diode failure was excessive overvoltage spikes.
When the diode failed, it failed closed and with the diode and fuse being
reversed the wire continued to heat up instead of breaking the fuse.
Part 573 Safety Recall Report 22E-001 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Identification of Any Warning
that can Occur :
Load dump faults within the BMS of the battery system.
Involved Components :
Component Name : Adapter Harness
Component Description : Wire harness designed by Volta that controls communication to an alternator
controller
Component Part Number : 100001146
Supplier Identification :
Component Manufacturer
Name : Tack Electronics
Address : 5030 Kraft Ave
Grand Rapids Michigan 49512
Country : United States
Chronology :
Winnebago contacted Volta on Oct 8, 2021 regarding a vehicle that experienced a thermal event. Winnebago
asked Volta to review the vehicle and support the investigation. On Oct 11, 2021 a team from Volta was on site
at Winnebago for three days to review the vehicles that had experienced the failure. Winnebago provided
evidence that they believed the failure was due to a diode within the Volta designed alternator control harness.
Volta then began looking for root cause of how the diode was damaged and/or failed. Volta verified the
certification of the parts, reviewed the manufacturing processes at Volta’s suppliers, reviewed engineering
drawings, and inspected vehicles for installation errors. On Oct 12 we discovered that the main power
connections, and ground bus bars installed by Winnebago on all vehicles present with the failure were finger
tight and did not have the required torque marks signifying that the terminals where properly tightened.
During the investigation of the drawings we also discovered that the fuse and diode order was reversed on the
Volta harness drawings. The subject Adapter Harness was also part of a non-safety related review in
connection with the Storyteller installations which commenced on or about Oct 13 and resulted in a
replacement program being instituted by Storyteller for those vehicles on or about Oct 14.
Part 573 Safety Recall Report 22E-001 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Volta is cooperating with Winnebago’s on-going recall and, further, is
cooperating with Storyteller Overland’s replacement program. Volta has
provided the units at no cost and is supporting installation costs.
How Remedy Component Differs
from Recalled Component :
New part number with order of fuse and diode reversed.
Identify How/When Recall Condition
was Corrected in Production :
A revised drawing with the reversed order of the fuse and diode was
provided to Volta supply chain and replacement parts where built. Volta
conducted a retraining at Winnebago on the importance and methods of
torqueing power terminals.
Recall Schedule :
Description of Recall Schedule : Winnebago recall performed by Winnebago. All parts requested have
been supplied to Winnebago for their recall started Dec 3, 2021. Parts
were also supplied to Storyteller Overland. As of January 7, 2022, Volta
had sold 288 suspect units to Storyteller of which 61 were replaced
within Storyteller’s control and of the remaining 227 parts, 217
replacement parts have been shipped (and 191 of the original affected
parts returned after replacement) in response to requests under the
Storyteller replacement program. The owners of ten (10) vehicles are
believed to have not yet responded to the Storyteller replacement
program, attempts to contact continue.
Volta notified Storyteller Overland of the condition on 10/14/2021. As
stated above, harness replacement campaign, with Storyteller Overland
was already underway for the harness in relation to continuous
improvement activities.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : Winnebago Industries
Address : 605 Crystal Lake Rd
Forest City IA 50436-0152
Country : US
Company Phone : 6415856385
Part 573 Safety Recall Report 22E-001 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : Storyteller Overland
Address : 516 35th St N. Suite A
Birmingham AL 35222
Country : US
Company Phone : 8889997442
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-001
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Volta Power Systems LLC
Submission Date : JAN 13, 2022
NHTSA Recall No. : 22E-001
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Volta Power Systems LLC
Address : 12550 Superior Ct
Holland MI 49424
Company phone : 226-4222
Population :
Number of potentially involved : 646
Estimated percentage with defect : 100 %
Equipment Information :
Brand / Trade 1 : Volta Power Systems
Model : adaptor harness
Part No. : 100001146
Size : 8 inchs
Function : communication
Descriptive Information : – This references an existing case 21V-793
-The population started at the date parts where first received from sub supplier.
– The previous parts built at Volta had a fuse and a diode in opposite positions on
a circuit.
– Winnebago Travato 2021, Winnebago Boldt 2021, and Storyteller Overland
Vans 2021
Production Dates : JUN 18, 2021 – OCT 01, 2021
Description of Defect :
Description of the Defect : Per the request of NHTSA representative Choon Lee, Volta submits this report:
In the case that power connections are not properly seated severe voltage
spike caused by intermittent connections could damage the filtering diode in
the alternator control harness (10001447) resulting in the possibility of a
shorted wire, on the same circuit the order of the fuse and diode were reversed.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In the case that the diode is broken in a closed condition, the sense wire
could be shorted to ground resulting in an overheated wire or broken wire.
Description of the Cause : The identified cause of the diode failure was excessive overvoltage spikes.
When the diode failed, it failed closed and with the diode and fuse being
reversed the wire continued to heat up instead of breaking the fuse.
Part 573 Safety Recall Report 22E-001 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Identification of Any Warning
that can Occur :
Load dump faults within the BMS of the battery system.
Involved Components :
Component Name : Adapter Harness
Component Description : Wire harness designed by Volta that controls communication to an alternator
controller
Component Part Number : 100001146
Supplier Identification :
Component Manufacturer
Name : Tack Electronics
Address : 5030 Kraft Ave
Grand Rapids Michigan 49512
Country : United States
Chronology :
Winnebago contacted Volta on Oct 8, 2021 regarding a vehicle that experienced a thermal event. Winnebago
asked Volta to review the vehicle and support the investigation. On Oct 11, 2021 a team from Volta was on site
at Winnebago for three days to review the vehicles that had experienced the failure. Winnebago provided
evidence that they believed the failure was due to a diode within the Volta designed alternator control harness.
Volta then began looking for root cause of how the diode was damaged and/or failed. Volta verified the
certification of the parts, reviewed the manufacturing processes at Volta’s suppliers, reviewed engineering
drawings, and inspected vehicles for installation errors. On Oct 12 we discovered that the main power
connections, and ground bus bars installed by Winnebago on all vehicles present with the failure were finger
tight and did not have the required torque marks signifying that the terminals where properly tightened.
During the investigation of the drawings we also discovered that the fuse and diode order was reversed on the
Volta harness drawings. The subject Adapter Harness was also part of a non-safety related review in
connection with the Storyteller installations which commenced on or about Oct 13 and resulted in a
replacement program being instituted by Storyteller for those vehicles on or about Oct 14.
Part 573 Safety Recall Report 22E-001 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Volta is cooperating with Winnebago’s on-going recall and, further, is
cooperating with Storyteller Overland’s replacement program. Volta has
provided the units at no cost and is supporting installation costs.
How Remedy Component Differs
from Recalled Component :
New part number with order of fuse and diode reversed.
Identify How/When Recall Condition
was Corrected in Production :
A revised drawing with the reversed order of the fuse and diode was
provided to Volta supply chain and replacement parts where built. Volta
conducted a retraining at Winnebago on the importance and methods of
torqueing power terminals.
Recall Schedule :
Description of Recall Schedule : Winnebago recall performed by Winnebago. All parts requested have
been supplied to Winnebago for their recall started Dec 3, 2021. Parts
were also supplied to Storyteller Overland. As of January 7, 2022, Volta
had sold 288 suspect units to Storyteller of which 61 were replaced
within Storyteller’s control and of the remaining 227 parts, 217
replacement parts have been shipped (and 191 of the original affected
parts returned after replacement) in response to requests under the
Storyteller replacement program. The owners of ten (10) vehicles are
believed to have not yet responded to the Storyteller replacement
program, attempts to contact continue.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : Winnebago Industries
Address : 605 Crystal Lake Rd
Forest City IA 50436-0152
Country : US
Company Phone : 6415856385
Name : Storyteller Overland
Address : 516 35th St N. Suite A
Birmingham AL 35222
Country : US
Company Phone : 8889997442
* NR – Not Reported

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