22E060 – Battery Pack May Short and Cause Fire – Cummins – BP74E Battery Packs

SEOCONTENT-START

Cummins Inc.
500 Jackson Street
Columbus, IN 47201 USA cummins.com
Recall 21E-060 4Q2022 Report January 18, 2023
Engines by Purchaser (Cummins Campaign C2460) Engines Sold to Vehicle Manufacturer GILLIG NEW FLYER EL DORADO NOVABUS CUMMINS TOTAL No. Eligible Units in U.S. 226
94
3
76
23
422 No. Campaigned Units in U.S. 174
80
1
68
2
325
% Engines Inspected and Repaired as of December 20, 2022
77%
85%
33%
89%
1%
77%
Mark L. Wilson
Director – Product Safety Cummins Inc.
500 Jackson Street Columbus, IN 47201 USA
mark.l.wilson@cummins.com

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Cummins Inc.
500 Jackson Street
Columbus, IN 47201 USA cummins.com
Recall 22E-060 1Q2023 Report April 13, 2023
Battery Packs by Purchaser (Cummins Campaign C2623) Battery Packs Sold to Vehicle Manufacturer GILLIG EL DORADO LETENDA
TOTAL No. Eligible Units in U.S. 1187
13
N/A* 1200 No. Campaigned Units in U.S. 1014
0
N/A 1014
% Inspected and Repaired as of
March 31, 2023
85%
0%
N/A 85%
* Units were exported. Rahul V. Mane
Leader – Product Safety Cummins Inc. 500 Jackson Street Columbus, IN 47201 USA
rahul.v.mane@cummins.com

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Cummins Inc.
500 Jackson Street
Columbus, IN 47201 USA cummins.com
Recall 22E-060 3Q2023 Report October 13, 2023
Battery Packs by Purchaser (Cummins Campaign C2623) Battery Packs Sold to Vehicle Manufacturer GILLIG EL DORADO LETENDA
TOTAL No. Eligible Units in U.S. 1187
13
N/A* 1200 No. Campaigned Units in U.S. 1187
13
N/A 1200
% Inspected and Repaired as of
August 31, 2023
100%
100%
N/A 100% * Units were exported.
Rahul V. Mane
Product Safety Compliance Leader Cummins Inc.
500 Jackson Street Columbus, IN 47201 USA
rahul.v.mane@cummins.com

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Cummins Inc.
500 Jackson Street
Columbus, IN 47201 USA cummins.com
Recall 21E-060 4Q2022 Report January 11, 2023
Battery Packs by Purchaser (Cummins Campaign C2623) Battery Packs Sold to Vehicle Manufacturer GILLIG EL DORADO LETENDA
TOTAL No. Eligible Units in U.S. 1187
13
N/A* 1200 No. Campaigned Units in U.S. 906
0
N/A 906
% Inspected and Repaired as of
December 20, 2022
76%
0%
N/A 76%
* Units were exported. Mark L. Wilson
Director – Product Safety Cummins Inc.
500 Jackson Streeet Columbus, IN 47201 USA Phone 1 812 377 7543
cummins.com
mark.l.wilson@cummins.co

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Cummins Inc.
500 Jackson Street
Columbus, IN 47201 USA cummins.com
Recall 21E-060 3Q2022 Report October 20, 2022
Battery Packs by Purchaser (Cummins Campaign C2623) Battery Packs Sold to Vehicle Manufacturer GILLIG EL DORADO LETENDA
TOTAL No. Eligible Units in U.S. 1187
13
N/A* 1200 No. Campaigned Units in U.S. 336
0
N/A 336
% Inspected and Repaired as of
October 20, 2022
28%
0%
N/A 28%
* Units were exported. Mark L. Wilson
Director – Product Safety Cummins Inc.
500 Jackson Streeet Columbus, IN 47201 USA Phone 1 812 377 7543
cummins.com
mark.l.wilson@cummins.co

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Cummins Inc.
500 Jackson Street
Columbus, IN 47201 USA cummins.com
Recall 22E-060 2Q2023 Report July 13, 2023
Battery Packs by Purchaser (Cummins Campaign C2623) Battery Packs Sold to Vehicle Manufacturer GILLIG EL DORADO LETENDA
TOTAL No. Eligible Units in U.S. 1187
13
N/A* 1200 No. Campaigned Units in U.S. 1126
6
N/A 1132
% Inspected and Repaired as of
June 30, 2023
94%
46%
N/A 94%
* Units were exported. Rahul V. Mane
Leader – Product Safety Cummins Inc. 500 Jackson Street Columbus, IN 47201 USA
rahul.v.mane@cummins.com

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Cummins Inc.
Box 3005
Columbus, IN 47202-3005 USA
Mail Code: 40911
Phone: 1 800 CUMMINS
care.cummins.com
TMeaxtr2c0h: 16, 2023
VAIL TRANSIT
1289 ELKHORN DRIVE
VAIL COLORADO 81657
Vehicles equipped with Cummins BP74E Battery Packs subject to NHTSA Recall 22E-060:
Engine Serial Number Vehicle Model or OEM Vehicle Identification Number (VIN) 83000023 *** IMPORTANT SAFETY RECALL*** NHTSA Recall No. 22E-060
Cummins Campaign #C2623 Second Notice March 16, 2023 Dear Cummins Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Cummins Inc. has decided that a defect which relates to motor vehicle safety exists in certain Cummins BP74E battery packs that were manufactured between August 6, 2020 and May 19, 2022. This notice applies to the battery packs in your vehicle(s) listed on the enclosed table. WHAT IS THE PROBLEM? Internal coolant leaks may develop within the battery pack, which may result in localized heating within the battery. This condition may lead to gases venting from the battery pack, smoke or a battery fire. WHAT ARE WE DOING ABOUT THE PROBLEM? Cummins has released Safety Campaign #C2623, BP74E Coolant Leak Safety Campaign to address this condition by changing the battery pack coolant to a low conductivity coolant, tightening the internal coolant outlet fitting and making some associated vehicle changes required for the new coolant. This campaign is currently available at Cummins Distributors and authorized Warranty Dealers. The repair will be completed free of charge and most applications will require approximately 2 days to complete. WHAT SHOULD YOU DO? Contact the nearest Cummins Distributor or authorized Warranty Dealer to arrange to have this safety action performed on your batteries/vehicle(s). The distributor or dealer will work with you to schedule the best date to complete this repair. In the meantime, Cummins advises operators to continue to follow the published Vehicle Manufacturer’s recommended actions and protocols should a HV Exposure lamp and Stop EV lamp become active If you have not registered your Cummins product, please complete the enclosed registration card or register your product at https://prodreg.cummins.com/prodreg/#/webform/contactInfo. Cummins Inc.
Box 3005
Columbus, IN 47202 – 3005 USA
Mail Code: 40911
Phone: 1 800 CUMMINS
care.cummins.com Cummins Inc.
Box 3005 Columbus, IN 47202 – 3005 USA
Mail Code: 40911
Phone: 1 800 CUMMINS
care.cummins.com
If you are no longer the owner of the batterie(s)/vehicles(s) listed on the enclosed table, please forward this notice to the new owner or provide the new owner’s contact information to Cummins so that we can notify them of this recall.
Federal law requires vehicle lessors receiving this recall notice to forward a copy of this notice to the lessee within ten (10) days. Also, it is a violation of Federal law for a dealer to deliver a new vehicle or equipment covered by this recall notice under a sale or lease until the defect has been remedied.
If you previously paid to have this recall performed on your vehicle, you may be eligible for reimbursement. Please contact Cummins Care at the number below for more information. WHO SHOULD YOU CONTACT IF YOU HAVE FURTHER QUESTIONS OR CONCERNS? If you have questions or concerns about this recall, please contact your local Cummins Distributor or authorized warranty dealer. You may also contact Cummins Care at 1-800-CUMMINS (1-800- 286-6467) or visit our website at care.cummins.com. If you have a complaint relative to this recall, you may report it to the following:
Administrator
National Highway Traffic Safety Administration 1200 New Jersey Avenue, SE
Washington, DC 20590
You may also call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Cummins is taking this action in the interest of your safety and satisfaction with our products. We apologize for any inconvenience and thank you for your attention to this matter.
Sincerely, Campaign Ad ator
Cummins Inc.

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9/6/22, 1:47 PM BP74E Coolant Leak Safety Campaign
https://quickserve.cummins.com/qs3/pubsys2/xml/en/campaign/2026/c2623.html?q=c2623 1/4
Warranty Field Campaign Campaign Number: c2623 Revision:
Released Date: 01-Sep- 2022
Expiration Date (U.S. and Canada): 12-Jan-2050 BP74E Coolant Leak Safety Campaign Expiration Date (International): 12-Jan- 2050
Attention
If additional information is required, please contact your Cummins Warranty Operations Group Leader.
Description
Action
U.S. / Canadian Distr./Branches and Div. Offices (Automotive)
This Safety Campaign is being issued to address potential internal coolant leaks that may develop within the battery pack, potentially creating a high voltage short circuit via the conduction path through the coolant. This condition may result in localized heating within the battery. An internal coolant leak may lead to gases venting from the battery pack, smoke or a battery fire on certain BES CM2450 EV101B units in Gillig buses. The internally leaking coolant will cause a HV Exposure lamp and Stop EV lamp to be displayed on the vehicle dashboard while the vehicle is in operation. This Safety Campaign authorizes certified repair locations to change the battery pack coolant to a low conductivity coolant and, tighten the internal coolant outlet fitting. Cummins is working with the vehicle manufacturers to implement the necessary vehicle changes to accommodate the new coolant.
In order to qualify for repair under this field action, a drivetrain system:
1. will be covered Regardless of coverage status, and
2. must show as OPEN on QuickServe® Online for this field action.
Note : The SSN list is attached for reference. 9/6/22, 1:47 PM BP74E Coolant Leak Safety Campaign
After verifying that the drivetrain system meets the above requirements, perform the following actions:
1. Follow campaign instructions on battery pack coolant port retorque and Low Conductive Coolant retrofit. Please refer to Attachment B for detailed instructions.
2. Remove and Replace the Resolver Harness by following the Motor Interface Wiring
Harness/Remove and Install Procedure. Please refer to the BES CM2450 EV101B Service Suite found on QuickServe® Online.
a. Select Service tab.
b. Select the Propulsion System tab.
c. Select the Electronic Controls tab.
d. Select the Motor Interface Wiring Harness.
e. Select Remove and Install.
f. Follow the procedure to complete the upfit.
Note : This wire harness has been included in the OEM supplied parts kits. Material Disposition Materials removed as a result of this field action must be scrapped. Reimbursements Parts
Note : Parts, materials and tools are going to be provided to the repair locations prior to campaign release. Parts, materials and tool list can be found in Attachment B. In addition, the kit will include the Resolver Wiring Harness needed to complete the repairs as outlined in the instructions.
There are no parts claimable in this field action.
Note : SRTs to gain access that are required to complete the repair, that are sufficiently explained in the claim narrative, may also be claimed on this action.
Labor Using Applicable Access Code and Time
SRT Code Description Time (hrs)
00-90X Administrative time
High Voltage Battery Pack – 31-024 Drain and Fill, Each – BES CM2450 EV101B https://quickserve.cummins.com/qs3/pubsys2/xml/en/campaign/2026/c2623.html?q=c2623 2/4 9/6/22, 1:47 PM BP74E Coolant Leak Safety Campaign
SRT Code Description Time (hrs)
Motor Interface Wiring 34-003 99-901 99-00A Travel Harness – Remove and Install
– BES CM2450 EV101B
CAMPAIGN ACTIVITIES (QTY 15)
COMPLETE CAMPAIGN ACTIVITIES (QTY1) Travel is not covered under this field action Towing is not covered under this field action.
Other Claimables
Consumables are covered under this field action.
Note : Additional parts, such as o-rings, gaskets and fasteners, that are required to complete the repair, but not listed, may be claimed in Other Claimables. Please consolidate all consumables and claim them as one line item in Other Claimables titled CAMPAIGN SUPPLIES or other appropriate selections. Please include brief summaries on the details of items claimed. A lack of documentation in the narrative may result in a reduction in claim reimbursement or claim denial. Claim Instructions For Cummins Dealers, claims for this Field Campaign must be filed via RAPIDSERVE™ Web (rsw.cummins.com). For information regarding RAPIDSERVE™ Web, please reference the “Warranty” tab in QuickServe® Online. If there are additional questions, please contact your local Cummins Distributor. Claim Codes
Description Code
Account Code: 65
Pay Code: North America Distributor = X
Pay Code: North America Dealer = D
Pay Code: International Distributor = I
Pay Code: International Dealer = R
Failure Code: WHVHBA Attachments https://quickserve.cummins.com/qs3/pubsys2/xml/en/campaign/2026/c2623.html?q=c2623 3/4 9/6/22, 1:47 PM BP74E Coolant Leak Safety Campaign
Click here to see c2623_ssn-list.xlsx (/service/english/attachments/c2623_ssn-list.xlsx) Click here to
see c2623_bp74e_coolant_leak_safety_campaign_attachment-b.pdf (/service/english/attachments/c2623_bp74e_coolant_leak_safety_campaign_attachment-b.pdf) Automotive Engine Family Design Application Bus Fuel System Market Application Document History
Date Details
Document Created; 01-Sep-2022 Last Modified: 01-Sep-2022 https://cst.cummins.com http://edsprod.cummins.com https://gpst.cummins.com https://quickserve.cummins.com https://parts.cummins.com https://store.cummins.com https://wwsps.cummins.com https://access.cummins.com https://commerce.cummins.com https://qsservices.cummins.com https://webparts.cummins.com https://qsservices.cummins.com https://adminportal.cummins.com 0sp4N000000PGNq https://cumminscommerce.force.com https://mylogin.cummins.com/web/idp/login https://quickserve.cummins.com/qs3/pubsys2/xml/en/campaign/2026/c2623.html?q=c2623 4/4 C2623
BP74E
Goodwood Coolant Outlet Port Retorque Instructions 22 August 2022 Cummins Confidential Remove Fittings Procedure Coolant hose 2nd 1. Park on a flat level surface with room to locate two 55 gallons drums
2. Set the parking brake and chock the wheels
3. Master run control in the off position and Low Voltage disconnect in the off position
4. Perform Lockout Tagout procedure using proper safety guidelines and PPE requirements
5. Follow Coolant Drain Procedure as outlined in Quick Serve Online
6. Remove coolant hose clamp at outlet port
7. Remove coolant hose
8. Remove elbow fitting Clamp 1st Remove Elbow Fitting 3rd Cummins Confidential 2 Retorque Coolant Port Nut 6. Use Internal Knurled-Grip Extractor tool with calibrated torque wrench to torque coolant port nut counter- clockwise to 5 Nm Note: Ensure Extractor Tool is inserted into coolant port perpendicular to the battery pack face before torquing. Insert tool as deep as it will go. Do not attempt to use tool placed into coolant port at an angle or you may receive a false torque reading.
Cummins Confidential 3 Replace Fittings Sticker Placement 7. Reinstall brass elbow fitting and torque to 45 FT LB
± 2 FT LB at the nut
8. Reinstall Coolant Hose
9. Reinstall coolant hose clamp torquing nut to 8-9 IN LB for Oetiker or 45 IN LB for Breeze clamps
10. After retorque procedure is complete for each high voltage battery pack, place purple sticker on each pack by coolant outlet port
11. Enter each pack serial number into claim Coolant hose 2nd Clamp 3rd Oetiker Clamp Breeze Clamp Re-Install Elbow Fitting 1st Cummins Confidential 4 Proceed to Low Conductive Coolant Retrofit Procedure Cummins Confidential 5 Low Conductive Coolant Retrofit, Flush and Fill Procedure 12 AUG 2022
Cummins Confidential Scope ▪ To make vehicle changes and complete a procedure to flush out the existing coolant with deionized water and then install the low conductivity coolant. Vehicle Changes ▪ Change the roof mounted vent piping to hoses and fittings which are compatible with the low conductivity coolant
▪ Removes the existing coolant filter and replaces this with a strainer and ion exchange cartridge
▪ Install a Flush and Fill Manifold/Valve assembly required to flush out the old coolant and install new coolant Coolant Flush and Fill ▪ Uses a remote electric pump connected to the new flush and fill manifold to flush out the existing coolant
▪ Uses the same set up to use the new low conductivity coolant to flush out the deionized water and install the new coolant Cummins Confidential 7 Parts Required Equipment and Materials Required: These will be installed before the flush and fill and will remain installed on the bus.
▪ Gillig Part Number
o Gen 2.0: 82-9168-000 Cummins LCC Upgrade Kit
o Gen 2.5
▪ Contains parts for the vent line replacement, strainer, filter, and flush fill manifold/valve assembly and a new coolant decal. Misc ▪ Gilling service tool kits
o This includes the electric coolant pump and all the hoses, valves and fittings to connect to the bus mounted flush and fill manifold/valve assembly
o Includes a quick coupler to drain coolant from the bus.
▪ 40 Gallons deionized water
▪ 14 Gallons Low conductivity coolant Gillig Part Number
▪ 55 Gallon drum to collect old coolant and deionized water
▪ 5-gallon bucket to collect drained coolant
▪ 5/16 drill bit and drill
▪ Source of 120 Vac to power the coolant pump
▪ Conductivity Meter
▪ Coolant Concentration meter
▪ Step Ladder
▪ Square Key
▪ Method to access roof and safety equipment to work on the roof. ▪ Appropriate disposal for removed coolant and deionized water. Cummins Confidential 8 Step 1 Vehicle Set Up and Drain
After running the Battery retorque procedure, vehicle should still be on flat level surface with room for two 55 gallon drums, wheels chocked, locked out tagged out, and drained of coolant. Then proceed to the following steps: 1. Ensure pressure cap is on surge tank but red lever is lifted up.
2. If any coolant is in the battery coolant loop, using the female quick coupler (Eaton p/n 6FFS25) or Cummins p/n 2892459 install at the existing coupler at the inlet pipe to the chassis battery and drain as much coolant as possible. About 3 to 5 gallons. This allow installing the new parts without spilling coolant. See Detail A for coupler location
3. After draining remove the quick coupler and install ¼ turn valve (Gillig P/N 53- 20873-006). See next slide for details Cummins Confidential 9 Detail A Cummins Confidential 10 Step 2: Remove CS pontoon and fence 1. Unplug the condensers LV plug
2. Remove sheet metal cover on CS that spans from the pontoon to the rearmost HV battery. Set cover to the side
3. Remove access cover on CS pontoon (6 screws). This will allow access to the pontoon’s mounting bolts.
4. Remove pontoon’s mounting bolts
5. Loosen bolts on fence directly in front of CS pontoon. The fence and pontoon overlap each other.
o Alternative: Remove fence in front of CS pontoon and set aside.
6. Remove pontoon and set aside; this may take 2 people
7. See Detail B See next slide for details Cummins Confidential 11 Detail B Cummins Confidential 12 Step 3: Install new vent piping 1. Remove the existing braided vent line that travels from the top of the bulkhead plate to the upper pipe of the roof battery piping.
2. Remove the braided vent line that travels from the bottom of the bulkhead plate to the small diverter valve mounted on the HVAC outlet piping.
3. Remove the MNPT to JIC elbow fitting on the upper pipe of the roof battery piping and replace with appropriate MNPT to hose beaded elbow.
4. Remove the MNPT to JIC fitting at the diverter valve and replace with the proper brass fittings.
5. Ensure the check valve stays on the diverter valve
6. Remove bulkhead fitting from bulkhead plate. Fitting nut is located on bottom side of plate
7. Bulkhead plate removal might be needed for access depending on tools available and is assistance is possible
8. Remove the 2 CS bolts on bulkhead assembly
9. They will be used to fasten the new bulkhead tube assembly.
10. Install new bulkhead tube assembly
11. Install new silicone hoses in place of the braided lines that were removed. Use existing clamps that secured old vent line to secure new silicone line. Ensure the new line does not have excess slack or is rubbing on any components or brackets. Install hose clamps to allow a downward slope to eliminate high and low spots for air bubbles to be trapped.
12. Install hose clamps
13. See Detail C See next slide for details Cummins Confidential 13 Detail C Cummins Confidential 14 Step 4: Re-install Pontoons and other roof components (this step can be the last step so looking for leaks is easier)
1. Re-install pontoons and fence.
a. These parts overlap each other so ensure that overlap is correct before fastening all hardware.
2. Re-install the sheet metal cover that travels from pontoon to roof battery
3. Re-connect the condensers LV plug
4. The access cover on the pontoon can be re-installed. This access window can be used to look for leaks when it comes time to flush and fill the bus. Step 5: Remove the existing filter and pump outlet pipe 1. Remove the coolant filter assembly (filter and filter head) and related hoses
2. Filter head has two ¼ turn valves, one into the head and one out. These valves will be reused with the Y-strainer.
3. Place these valves in a cup of deionized water to soak until time for installation
4. Remove the pump outlet pipe and silicone hoses attached to pipe
5. See Detail D
6. Unplug and remove GRI controller
1. Be sure to move the exposed plugs out of the way so they stay clean and dry
7. Remove the existing self-tapping screw seen in Detail G. This screw will be re-installed when the controller bracket is installed. This screw is only present on GEN2.0 configurations. See next slide for details Cummins Confidential 15 Detail D Cummins Confidential 16 Detail D continued…. Cummins Confidential 17 Step 6: Remove and rework Surge tank 1. Unplug level sensor and remove hoses attached to surge tank
o One hose on the bottom of the surge tank
o One small nylon line on the back of the surge tank
o One small nylon line from the fill neck of the surge tank
2. Loosen 3 bolts that mount the surge tank. Be sure to not lose the nut plates that are inside the extrusion
3. Cut off welded tab on side of surge tank
o Be sure not to damage surge tank in process of cutting off tab
o The entire tab does not need to be removed from the side of the tank. The tab can be cut off at or just after the bend
o After cutting tab off, round off the edges so there are no sharp edges present
o See detail E
4. Drill 4 holes in surge tank flange for mounting of Y-strainer
5. Rinse out surge tank with deionized water.
6. Install new hose fitting and ¼ turn valve on back of surge tank
7. See Detail F See next slide for details Cummins Confidential 18 Detail E This tab gets cut off.
Be sure not to damage tank 1.375 2.1517 thod.
of tab then round 1.3253 .45
DRILLING PATTERN FOR Y-STRAINER MOUNTING Cummins Confidential 19 Detail F Cummins Confidential 20 Step 7: Rework the HVAC Platform 1. Drill 3 – 5/16 holes into the HVAC platform
2. Use templates seen in Detail G to locate and drill holes
a. Alternative rework method. Use brackets to find proper hole location
i.Install the GRI pump controller and controller bracket using the existing controller hardware and holes. This will locate one of the new hole locations. Note: Before installing this bracket, remove the self-tapping screw, labelled in Detail G. This self-tapping screw is only present for GEN2.0 ii.Install 21-85153-000 bracket on the HVAC platform. This bracket is installed underneath an existing bracket on the HVAC platform.
iii.See Detail H.
iv.Loosely re-install existing hardware.
v.Center slots between 21-85152-000 and 21-85150-000 to properly locate 21-85153-000. Snugging up hardware in slots will help keep brackets steady. Once brackets are located, mark holes for rework
vi.While brackets are mocked up on the HVAC platform, gently place the flush and fill manifold in location to determine if fitting tweaks are needed
3. A ¼” hole may need to be drilled for the GRI pump controller. The new pump controller bracket has this mounting hole, and it is seen identified in Detail G.
4. Once new holes are drilled, 21-85150-000 and 21-85153-000 can be installed and fastened to the HVAC platform. See next slide for details Cummins Confidential 21 Detail G Cummins Confidential 22 Detail H Cummins Confidential 23 Step 8: Install the Flush and Fill Manifold Valve Assembly 1. Flush and fill manifold will come pre-assembled in the kit.
2. See Detail J to visually confirm manifold is pre-assembled properly prior to adjustments
a. Minor adjustments to some fittings may be needed due to on-bus variation
b. This check can be completed in the previous step or in the following bullet points
3. Install ion cartridge to valve assembly bracket, 21-85152-000 prior to installing bracket on the bus. Ion cartridge is installed using cushion clamps, nylon spacer, and appropriate hardware.
a. If clearance checks for the brass assembly were not performed in the previous step, it is recommended to not fasten the brass assembly to the bracket.
b. Perform clearance checks and fitting rotations, if needed, at this step
4. Install valve assembly bracket
5. Install the brass valve assembly
6. Install silicone reducers from brass valve assembly to bus pump and to HVAC unit.
a. These reducers will have to be trimmed in order to fit properly. Be sure to not trim the reducer too short as this would yield poor hose clamp securement
7. See Detail K for a fully assembled bracket
8. See Detail L for installation of brackets, ion cartridge and brass assembly in the bus See next slide for details Cummins Confidential 24 Detail J Cummins Confidential 25 Detail J continued…. Cummins Confidential 26 Detail K Cummins Confidential 27 Detail K continued…. Cummins Confidential 28 Detail L Cummins Confidential 29 Step 9: Re-install surge tank 1. Re-install reworked surge tank
2. Existing hardware will be used for re-installation
a. It is best to have the hardware loosely installed on the surge tank before re- installation
3. Be cautious when re-installing tank that the mounting tab on the back side of the tank does not cut or damage the HV cables running down the side of the bus
4. Surge tank should be at the same height
a. If tank needs to be translated upward. Slack should be found in the level sensor, both nylon air lines, and supply line as that will limit translation upward.
5. Re-install main supply line on the bottom of the surge tank
6. Re-install both nylon air lines
a. One on the filler neck
b. One on the rear of the tank
7. Re-install level sensor cable Cummins Confidential 30 Step 10: Install the new Y-strainer 1. Remove the ¼ valves soaking the cup of deionized water and rinse off with deionized water
2. Build up Y-strainer assembly
a. 2 – ¼ valves. These valves would be the valves from the old coolant filter assembly that were washed out with deionized water.
b. Y-Strainer
c. 2 – 90 deg elbow, 0.50 hose bead-0.375MNPT
3. Install Y-strainer assembly to the surge tank
a. While installing the U-bolts that mount the strainer to the surge tank, ensure they do not contact the HVAC transition duct.
4. Ensure the ¼ turn valve handles are free to fully open and close without contacting any other components.
5. Ensure the strainer basket is pointed down
6. See Detail M for Y-strainer assembled proper fitting orientation See next slide for details Cummins Confidential 31 Detail M Cummins Confidential 32 Step 11: Install coolant decal on surge tank 1. Locate and install new decal per Detail N Detail N Cummins Confidential 33 Step 12: Post upfit vehicle check 1. Check all hose clamps are tightened and properly installed
2. Check for rubbing and clearance issues between all components
3. Check that all parts are installed, and no parts are missing
4. Check all hardware is installed and torqued to spec Vehicle Set Up Complete Cummins Confidential 34 Flush and Fill Procedure Precaution Notes
• Low Conductivity Coolant must remain in the original container until placed in the vehicle cooling system. Keep all containers closed until use. Do not move to a temporary storage container.
• Do not use any carbon steel containers to hold deionized water or low conductivity coolant.
• All fill equipment must be compatible with the coolant, do not change any fill equipment without approval.
• Use only deionized water for cleaning of fill equipment Valve Identification and Function
V1 Inline Flow Control Valve
• Open allows coolant flow from bus pump to flow to the batteries. Open during normal operation
• Closed blocks coolant flow from bus pump and directs coolant to flow out V3. Closed only during flush and fill
V2 Remote Supply Valve
• Open allows coolant flow from bus pump to flow to the batteries. Open during normal operation
• Closed blocks coolant flow from bus pump and directs coolant to flow out V3. Closed only during flush and fill
V3 Battery Return Drain Valve
• Open to allow discharge flow. Open only during flush and fill
• Closed to block flow. Closed during normal operation
V4 Discharge Diversion Valve
• Position 1 Flow directed to waste drum
• Position 2 Flow directed to remote pump inlet See next slide for details Cummins Confidential 35 Cummins Confidential 36 Cummins Confidential 37 Step 1: Set up remote pump, hose connection, prime 1. Route drain hose coming off of V4 (Diverter valve) into waste drum.
2. Connect hose from V3 (Battery return drain valve) to V4
3. Route suction hose coming from the remote pump into supply barrel.
4. Ensure the remote pump is prime of fluid at the discharge port before connecting a hose from V2 (supply valve) to remote pump discharge port. See next slide for details Cummins Confidential 38 Cummins Confidential 39 Step 2: Preparation 1. Place an additional 5-gallon bucket under surge tank drain line which is located at rear curbside corner of the bus.
2. Close all three ¼ turn valves at strainer and ion exchange cartridge piping to prevent flow through the ion exchange cartridge during flush. Will be opened prior to the coolant fill. Step 3: Purge with Deionized Water 1. Ensure:
a. V2 (Remote supply) and V3 (Battery return drain) is open.
b. The valve at the chassis fill port and V1 (Inline flow) is closed.
c. V4 (Diverter valve) is switched to position 1.
d. 3-way valve is closed.
e. Pressure cap is on surge tank and red pressure lever is down (closed).
2. Turn on the remote pump.
3. While the remote pump is running, watch the color of the discharging coolant. In about 20 gallons to 35 gallons (60 to 180 seconds) the color should go from red to clear. Color should be clear with no hint of red tint. If required continue to purge until clear.
4. While the pump is running, lift the red lever up (open) on the surge tank cap to allow the deionized water to purge into the surge tank. Hold until the tank sight glass is filled then flip red lever down (closed). Cummins Confidential 40 Step 3: Purge with Deionized Water continued…. 5. While remote pump is still running move V4 Discharge (Diversion Valve) to position 2 to direct flow to the recirculation mode. Immediately turn off the remote pump.
6. Ensure:
a. V2 (remote supply) and V3 (battery return drain) are in closed position.
b. V1 (Inline flow) is open.
c. V4 (Diverter valve) is at position 1.
7. Turn LV on, day run on, and EV start to allow bus pump to circulate DI water in the system. CAUTION: if you perform recirculate with remote pump, any contamination in the bus can make it way to supply barrel and affect DI water overall.
8. After running bus for 10 mins. Turn off EV, day run off, and LV.
9. Ensure
a. V2 (remote supply) and V3 (battery return drain) are in open position.
b. V1 (Inline flow) is closed.
c. V4 (Diverter valve) remains at position 1.
10. Turn remote pump on.
11. Allow ~10 gallons (~1 min) of DI water to pump out of the waste line.
12. Turn remote pump off. Cummins Confidential 41 Step 4: Fill with Low Conductivity Coolant 1. Ensure:
a. V2 (remote supply) and V3 (battery return drain) are still in the open position.
b. V1 (inline flow) remained closed.
c. V4 (diverter valve) remain in position 1.
2. Place remote pump suction hose with foot valve into the drum of low conductivity coolant. Ensure the drum has at least 15 gallons of coolant.
3. Check for proper pump prime
4. Turn on the remote pump.
5. While the pump is running lift the red lever up (open) on the surge tank cap to fill the top of tank with coolant. Then lift red lever down (closed).
6. Allow 13-14 gallons to flow out the discharge
7. Take a sample of the final coolant at discharge hose
8. While remote pump is still running move V4 (Diversion Valve) to position 2 to direct flow to the recirculation mode. Immediately turn off the remote pump.
9. Turn off the pump. Cummins Confidential 42 Step 4: Fill with Low Conductivity Coolant continued… 10. Check the conductivity of the sample
a. 10 -15 micro-Siemens or lower continue to the new step
b. Above 10 -15 micro-Siemens move V4 back to the position 1 and restart pump and add about 1 gallon coolant. Repeat until 10 -15 micro-Siemens or lower. 11. Ensure:
a. V2 (remote supply) and V3 (battery return drain) are in closed position.
b. V1 (inline flow) is opened.
12. Drain supply hose going to V2 and drain hose going into V3 before disconnecting the fill and discharge hoses and install the caps.
13. Turn on the bus low voltage and then turn the Master Run Control to Day Run. This will turn on the bus coolant pump
14. Confirm the pump is running check the surge tank fluid level and check for leaks
15. Open all three ¼ turn valves in the strainer and ion exchange cartridge piping to allow flow to the cartridge.
16. Turn off the bus. Flush and Fill is complete. Cummins Confidential 43

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*** IMPORTANT SAFETY RECALL*** NHTSA Recall No. 22E-060
Cummins Campaign #C2623 September 16, 2022 Dear Cummins Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Cummins Inc. has decided that a defect which relates to motor vehicle safety exists in certain Cummins BP74E battery packs that were manufactured between August 6, 2020 and May 19, 2022. This notice applies to the battery packs in your vehicle(s) listed on the enclosed table. WHAT IS THE PROBLEM? Internal coolant leaks may develop within the battery pack, which may result in localized heating within the battery. This condition may lead to gases venting from the battery pack, smoke or a battery fire. WHAT ARE WE DOING ABOUT THE PROBLEM? Cummins has released Safety Campaign #C2623, BP74E Coolant Leak Safety Campaign to address this condition by changing the battery pack coolant to a low conductivity coolant, tightening the internal coolant outlet fitting and making some associated vehicle changes required for the new coolant. This campaign is currently available at Cummins Distributors and authorized Warranty Dealers. The repair will be completed free of charge and most applications will require approximately 2 days to complete. WHAT SHOULD YOU DO? Contact the nearest Cummins Distributor or authorized Warranty Dealer to arrange to have this safety action performed on your batteries/vehicle(s). The distributor or dealer will work with you to schedule the best date to complete this repair. In the meantime, Cummins advises operators to continue to follow the published Vehicle Manufacturer’s recommended actions and protocols should a HV Exposure lamp and Stop EV lamp become active If you have not registered your Cummins product, please complete the enclosed registration card or register your product at https://prodreg.cummins.com/prodreg/#/webform/contactInfo. Cummins Inc.
Box 3005
Columbus, IN 47202 – 3005 USA
Mail Code: 40911
Phone: 1 800 CUMMINS
care cummins.com Cummins Inc.
Box 3005 Columbus, IN 47202 – 3005 USA
Mail Code: 40911
Phone: 1 800 CUMMINS
care cummins.com
If you are no longer the owner of the batterie(s)/vehicles(s) listed on the enclosed table, please forward this notice to the new owner or provide the new owner’s contact information to Cummins so that we can notify them of this recall.
Federal law requires vehicle lessors receiving this recall notice to forward a copy of this notice to the lessee within ten (10) days. Also, it is a violation of Federal law for a dealer to deliver a new vehicle or equipment covered by this recall notice under a sale or lease until the defect has been remedied.
If you previously paid to have this recall performed on your vehicle, you may be eligible for reimbursement. Please contact Cummins Care at the number below for more information. WHO SHOULD YOU CONTACT IF YOU HAVE FURTHER QUESTIONS OR CONCERNS? If you have questions or concerns about this recall, please contact your local Cummins Distributor or authorized warranty dealer. You may also contact Cummins Care at 1-800-CUMMINS (1-800- 286-6467) or visit our website at care.cummins.com. If you have a complaint relative to this recall, you may report it to the following:
Administrator
National Highway Traffic Safety Administration 1200 New Jersey Avenue, SE
Washington, DC 20590
You may also call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Cummins is taking this action in the interest of your safety and satisfaction with our products. We apologize for any inconvenience and thank you for your attention to this matter.
Sincerely, Campaign Ad ator
Cummins Inc.

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*** IMPORTANT SAFETY RECALL ***
NHTSA Recall No. 22E-060
July 22, 2022 GILLIG LLC
451 Discovery Drive,
Livermore, CA 94551
Dear Cummins OEM Customer: We are writing to inform you that Cummins Inc. has determined that a safety-related defect exists in certain BP74E Battery Packs that were manufactured between August 6, 2020 and May 19, 2022. Cummins has initiated a recall of the subject battery packs. Our records indicate that some of these battery packs have been shipped to you. A copy of Cummins’ initial Part 573 Defect Notification report is enclosed. This notification was submitted to the National Highway Traffic Safety Administration (NHTSA) on July 19, 2022. As more fully described in the Defect Notification, the battery packs may develop internal coolant leaks, possibly leading to gases venting from the battery, smoke or a battery fire. Enclosed is a list of affected serial numbers for battery part numbers 6301592 and A063V367 that our records indicate were shipped to your plants. For battery packs installed in vehicles that have left your control, we encourage you to make a safety defect determination in accordance with 49 USC 30118 et seq. and, as appropriate, to submit a Defect Notification to NHTSA in accordance with 49 CFR Part 573. Cummins will conduct the recall, notify vehicle owners, perform the remedy, and submit quarterly status reports to NHTSA and the OEM. Cummins is requesting that you provide the associated vehicle model identification, VINs and owner contact information to facilitate owner notification. Please work with your Cummins account team leader to ensure that the requested information is provided to Cummins as soon as possible. As a supplier of original equipment, Cummins has no obligation to submit a defect notification to Transport Canada. However, Cummins does, as a courtesy, notify Transport Canada when Cummins submits a defect notification to NHTSA, advising that some OEMs may have affected vehicles. If you have an obligation to report the defect to Transport Canada, we ask that you please provide us with the Transport Canada recall number assigned to your vehicle recall.
Cummins cannot mail owner letters compliant with Transport Canada regulations with respect to your recalled vehicles without the recall number assigned by Transport Canada. Cummins will provide the applicable data to you after our mailings are completed so that you can submit the required notification reports to Transport Canada, as well as provide you the completion rate data so that you can submit the required quarterly completion reports to Transport Canada. For battery packs that are still in your inventory, please contact Brian Whaley at [email protected] to arrange for repairs. Please note that Federal law prohibits delivery of battery packs, or vehicles equipped with these battery packs, under a sale or lease
until this condition has been remedied. Cummins apologizes for this inconvenience, but we are initiating this action in the interest of our
customers’ safety and satisfaction with our products. Thank you for your assistance. Please confirm receipt of this communication.
Sincerely,
Electrified Components-Cummins Inc.
500 Central Avenue, Columbus, IN, 47201
Enclosures: 1. Cummins Part 573 Defect Notification
2. Battery serial number list

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-060
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Cummins, Inc. AUG 16, 2022 NHTSA Recall No. : 22E-060 Manufacturer Recall No. : C2623
Manufacturer Information :
Manufacturer Name : Cummins, Inc.
Address : Box 3005
Mail Code COB118 Columbus IN 47202-3005
Company phone : 812-377-5000
Population :
Number of potentially involved : 1,213 Estimated percentage with defect : NR
Equipment Information : Brand / Trade 1 :
Model : Cummins Inc. BP74E Part No. : 6301592, A063V367 Size : NR Function : Battery Pack
Descriptive Information : This recall encompasses the entire population of battery packs built until corrective action was implemented on 20 May 2022. All of these battery packs were sold for installation into transit bus applications.
Production Dates : AUG 06, 2020 – MAY 19, 2022
Description of Defect :
Description of the Defect : Internal coolant leaks may develop within the battery pack, potentially creating a high voltage short circuit via the conduction path through the coolant. This condition may result in localized heating within the battery.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Under certain conditions, an internal coolant leak may lead to gases venting from the battery pack, smoke or a battery fire.
Description of the Cause : The causes of the internal coolant leaks are a loose coolant outlet connector or an improperly loaded bolted joint inside of the battery pack. Identification of Any Warning
that can Occur : The internally leaking coolant will cause an isolation fault to set, and a High Voltage Exposure and Stop EV lamp to be displayed on the vehicle dashboard
while the vehicle is in operation. Part 573 Safety Recall Report 22E-060 Page 2 Involved Components : Component Name : Pack, Storage Battery Component Description : Battery Pack Component Part Number : 6301592 Component Name : Pack, Storage Battery Component Description : Battery Pack Component Part Number : A063V367 Supplier Identification : Component Manufacturer
Name : N/A Address : NR
NR
Country : NR Chronology :
1/22/22 – 2/11/22 – Cummins received a report of an isolation fault set on a bus at an OEM facility. A service technician identified that a coolant leak inside the battery pack triggered an isolation fault. The battery pack was removed from the vehicle, loaded into a battery container, and shipped to Cummins for a tear-down analysis. While en route to Cummins, the driver of the transporting truck observed smoke coming from the trailer and called emergency services. The battery container and trailer were subsequently doused and quarantined. Subsequent tear-down analysis at Cummins was inconclusive as to the cause of the leak. 2/16/22 – Cummins changed the service procedure to specify that failed battery packs be shipped back to Cummins with open carriage and dedicated transport. 3/7/22 – Cummins initiated a Product Safety Hazard Analysis and continued the investigation. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-060 Page 3 4/15/22-5/20/22– Cummins received reports of two additional suspected leaks on a unit at an OEM and on a unit in the field. Cummins investigated these incidents, and the battery packs were shipped to Cummins for tear-down analysis. There were no reports of smoke or fire on these units. 5/20/22 – Cummins completed the Product Safety Hazard Analysis. 5/20/22-7/12/2022 – Cummins escalated the issue through its Product Safety Defect Determination process, including gathering additional information and conducting additional analysis. 7/12/22 – Based upon the results of the investigation, the Cummins Product Safety Defect Board decided to conduct a safety campaign to address this condition. To date, there have been no reports of vehicle fires or injuries due to this condition. Description of Remedy :
Description of Remedy Program : The remedy is to change the battery pack coolant to a low conductivity
coolant and to tighten the internal coolant outlet fitting. Cummins is working with the vehicle manufacturers to implement the necessary vehicle changes to accommodate the new coolant. Pursuant to 49 CFR 577.11(e), Cummins requests that it be exempt from providing notification of a reimbursement plan. Any pre-notification product failure would have been replaced under the manufacturer’s limited warranty. Accordingly, no person would be eligible for reimbursement pursuant to 573.13. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : As part of completing the remedy on the affected units, the service technician will place a sticker on the vehicle radiator indicating that only low conductivity coolant is to be used in the vehicle.
Manufacturing changes were implemented on 5/20/2022 to eliminate grease from the coolant outlet fitting and increase the engagement torque on the connector and changes were implemented on the subject bolted joint. Recall Schedule :
Description of Recall Schedule : Cummins expects to notify the affected OEMs no later than July 22, 2022.
Cummins will conduct the recall and notify owners, with agreement of the OEMs. The timing of owner notification will be determined in consultation with the affected OEMs. Cummins expects to mail interim owner letters no later than 9/16/22. Cummins expects to release the The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-060
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Safety Campaign to the field by October 2022 and will mail owner notifications at that time.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : SEP 16, 2022 – SEP 16, 2022 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 : Eldorado National California Address : 9670 Galena Street
Riverside CA 92509 Country : US
Company Phone : 9515299052 Name : Gillig Corporation Address : 451 Discovery Drive
Livermore CA 94551 Country : US
Company Phone : 5102643833 Name : Letenda Inc Address : 1105 Rue Saint-Jean
Longueuil 00 J4H-2Z3 Country : CA Company Phone : NR
* NR – Not Reported
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-060
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Cummins, Inc. JUL 19, 2022 NHTSA Recall No. : 22E-060 Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Cummins, Inc.
Address : Box 3005
Mail Code COB118 Columbus IN 47202-3005
Company phone : 812-377-5000
Population :
Number of potentially involved : 1,213 Estimated percentage with defect : NR
Equipment Information : Brand / Trade 1 :
Model : Cummins Inc. BP74E Part No. : 6301592 Size : NR Function : Battery Pack
Descriptive Information : This recall encompasses the entire population of battery packs built until corrective action was implemented on 20 May 2022. All of these battery packs were sold for installation into transit bus applications.
Production Dates : AUG 06, 2020 – MAY 19, 2022
Description of Defect :
Description of the Defect : Internal coolant leaks may develop within the battery pack, potentially creating a high voltage short circuit via the conduction path through the coolant. This condition may result in localized heating within the battery.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Under certain conditions, an internal coolant leak may lead to gases venting from the battery pack, smoke or a battery fire.
Description of the Cause : The causes of the internal coolant leaks are a loose coolant outlet connector or an improperly loaded bolted joint inside of the battery pack. Identification of Any Warning
that can Occur : The internally leaking coolant will cause an isolation fault to set and a High Voltage Exposure lamp to be displayed on the vehicle dashboard while the
vehicle is in operation. Part 573 Safety Recall Report 22E-060 Page 2 Involved Components : Component Name : Pack, Storage Battery Component Description : Battery Pack Component Part Number : 6301592 Supplier Identification : Component Manufacturer
Name : N/A Address : NR
NR
Country : NR Chronology :
1/22/22 – 2/11/22 – Cummins received a report of an isolation fault set on a bus at an OEM facility. A service technician identified that a coolant leak inside the battery pack triggered an isolation fault. The battery pack was removed from the vehicle, loaded into a battery container, and shipped to Cummins for a tear-down analysis. While en route to Cummins, the driver of the transporting truck observed smoke coming from the trailer and called emergency services. The battery container and trailer were subsequently doused and quarantined. Subsequent tear-down analysis at Cummins was inconclusive as to the cause of the leak. 2/16/22 – Cummins changed the service procedure to specify that failed battery packs be shipped back to Cummins with open carriage and dedicated transport. 3/7/22 – Cummins initiated a Product Safety Hazard Analysis and continued the investigation. 4/15/22-5/20/22– Cummins received reports of two additional suspected leaks on a unit at an OEM and on a unit in the field. Cummins investigated these incidents, and the battery packs were shipped to Cummins for tear-down analysis. There were no reports of smoke or fire on these units. 5/20/22 – Cummins completed the Product Safety Hazard Analysis. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-060 Page 3 5/20/22-7/12/2022 – Cummins escalated the issue through its Product Safety Defect Determination process, including gathering additional information and conducting additional analysis. 7/12/22 – Based upon the results of the investigation, the Cummins Product Safety Defect Board decided to conduct a safety campaign to address this condition. To date, there have been no reports of vehicle fires or injuries due to this condition. Description of Remedy :
Description of Remedy Program : Cummins is currently developing the remedy for the recalled units. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Pursuant to 49 CFR 577.11(e), Cummins requests that it be exempt from providing notification of a reimbursement plan. Any pre-notification product failure would have been replaced under the manufacturer’s limited warranty. Accordingly, no person would be eligible for reimbursement pursuant to 573.13.
Cummins will complete this section when the remedy is developed. Manufacturing changes were implemented on 5/20/2022 to eliminate grease from the coolant outlet fitting and increase the engagement torque on the connector and changes were implemented on the subject bolted joint. Recall Schedule :
Description of Recall Schedule : Cummins expects to notify the affected OEMs no later than July 22, 2022.
Cummins will conduct the recall and notify owners, with agreement of the OEMs. The timing of owner notification will be determined in consultation with the affected OEMs. Cummins is currently developing the schedule for implementation of the recall.
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: The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-060
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : Gillig Corporation Address : 451 Discovery Drive
Livermore CA 94551 Country : US
Company Phone : 5102643833 Name : Eldorado National California Address : 9670 Galena Street
Riverside CA 92509 Country : US Company Phone : NR Name : Letenda Inc Address : 1105 Rue Saint-Jean
Longueuil 00 J4H-2Z3 Country : CA Company Phone : NR
* NR – Not Reported

SEOCONTENT-END