23E030 Generator Set Fuel Hose May Cause Gas Leak – Cummins Onan QG 2800i, & QG 2800i EVAP Generator Sets

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April 4, 2023 NHTSA CAMPAIGN NUMBER: 23E030000

Generator Set Fuel Hose May Cause Gas Leak

A gas leak in the presence of an ignition source increases the risk of a fire.

 

NHTSA Campaign Number: 23E030

Manufacturer Cummins, Inc.

Components FUEL SYSTEM, GASOLINE, EQUIPMENT

Potential Number of Units Affected 15,622

 

Summary

Cummins, Inc. (Cummins) is recalling certain Onan QG 2800i, and Onan QG 2800i EVAP generator sets. The fuel hose between the fuel filter and Injection Pump Module (IPM) may not be properly secured, which can cause a gas leak.

 

Remedy

Dealers will inspect and replace the fuel hose and clamps, as necessary, free of charge. Owner notification letters are expected to be mailed June 2, 2023. Owners may contact Cummins customer service at 1-800-286-6467. Cummins number for this recall is PG5215.

 

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.

 


TSB230067
17-Apr-2023

Safety Campaign #5215 – HGLAA Fuel Hose Leak

 

Product Affected

  • HGLAA Spec A
  • 2.8 HGLAA-8302 (Gasoline)
  • 2.8 HGLAA-8303 (EVAP)

 

Issue

Symptom:

  • Fuel line connection from fuel filter to the inlet of the Injection Pump Module (IPM) may not be secured properly

Root Cause:

  • Incorrect hose used during assembly

 

Verification/Confirmation

  • If the gasoline generator set has a serial number before B230206933, inspect to see if the fuel hose from filter to Injection Pump Module (IPM) has the specified colored writing on hose.

Refer to document TSB230067-A Safety Campaign #5215 HGLAA Fuel Hose Leak Affected Generator Set Serial Numbers for a table of affected units.

 

Resolution

Replace Oeitker (OET) clamp with new OET Clamps while using OET Pilers. Use Kit PN A073U493

See Service Instructions sections below, for proper fuel line, clamps, and installation instructions.

 

Service Instructions

1. If unit at OEM, unbox the unit from original packaging (not applicable for Installed Units).

2. Turn off the HGLAA generator set , Perform LOTO .

3. Remove the door enclosure (PN A062F793) by twisting the knob to open.

Note: If enclosure needs to be removed for adequate access be mindful of the enclosure tabs at the base pan.

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Chronology :

1/18/2023 – 1/22/2023 – While attending the Florida RV SuperShow, Cummins personnel received reports of fuel leaks on the subject generators. During this same time, Cummins received a report of fuel leaks directly from Pleasure-Way.

1/18/2023 – 2/10/2023 – Cummins assembled a team to investigate the issue. Cummins initiated engineering pull tests on the subject joint.

2/10/2023 – 2/21/2023 – Cummins initiated a stop-ship on the subject generators from the manufacturing plant and the distribution center as it continued the investigation into the cause of the issue. Cummins determined that production samples had fuel hose clamping force less than the specification. The engineering team investigated variables that may have caused the issue and determined that inadequate specification of the hose was the cause. Cummins validated and released a new part number for a remedy hose to meet the requirements. Cummins conducted a review of its claims records and identified 12 warranty claims of a fuel leak and/or fuel hoses disconnecting from the IPM and 16 reports of leaks from OEMs and Cummins dealers/distributors. Cummins isolated and inspected and, where necessary, repaired, inventory of the subject generators at the manufacturing plant, the distribution center and some OEMs.

2/22/2023 – 3/9/2023– Cummins conducted a Product Safety Hazard Analysis to evaluate the potential safety risk on fielded units.

3/10/2023-3/28/2023 – Cummins escalated the issue through its Product Safety Defect Determination Process.

3/28/2023 – 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 fires or injuries related to this issue.

 


1 Affected Product

Equipment

BRAND PART NO. PRODUCTION DATES
CUMMINS ONAN QG 2800I

 


5 Associated Documents

Recall Acknowledgement

RCAK-23E030-5444.pdf 645.943KB

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Defect Notice 573 Report

RCLRPT-23E030-6130.PDF 218.525KB

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Recall 573 Report – 4/14/2023

RCLRPT-23E030-4393.PDF 221.062KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23E030-3638.pdf 62.991KB

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Remedy Instructions and TSB

RCRIT-23E030-6878.pdf 6452.956KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23E030&docType=RCL

 


 

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