Fuel Heater May Overheat And Cause Fire - Cummins B6.7 Diesel Engines

March 31, 2020 NHTSA CAMPAIGN NUMBER: 20E018000

A fire increases the risk of injury. An engine stall can increase the risk of a crash.

NHTSA Campaign Number: 20E018

Manufacturer Cummins Inc.

Components FUEL SYSTEM, DIESEL

Potential Number of Units Affected 68,605

Summary

Cummins Inc. (Cummins) is recalling certain B6.7 Diesel Engines, part number D313029BX03, used in school buses, trucks and emergency vehicles, equipped with fuel module option number FS90301 or FS90453. The electric fuel heater within the fuel module may overheat and cause plastic in the fuel heater to melt and potentially catch fire. It may also lead to engine stalling.

Remedy

Cummins will notify owners, and dealers will replace the component with install a plug in place of the heater rendering the heater inoperable, or remove the fuse and install a cover over the wire harness. This repair will be done free of charge. The recall began May 29, 2020. Owners may contact Cummins customer service at 1-800-286-6467. Note: This recall supersedes 19E-020.

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.

Warranty Field Campaign

Campaign Number: c2302	Revision:	Released Date: 01-May2020
B6.7 Engine-Mounted Fuel Heater Safety Campaign		Expiration Date (U.S. and Canada): 01-May-2045
B6.7 Engine-Mounted Fuel Heater Safety Campaign		Expiration Date (International): 01-May2045

Attention

If additional information is required, please contact your Cummins Warranty Operations Group Leader.

Description

This Safety Campaign is being issued to address a product issue where under certain conditions, internal electrical heating within the fuel heater may create sufficient heat inside the fuel heater to cause plastic in the fuel heater to melt and potentially catch fire.

This Safety Campaign supersedes campaigns C2127, C2128, and ATC2278. The remedy described in this Safety Campaign must be performed on your engine, even if your engine was remedied under one of the prior campaigns.

Cummins has reported this issue to the U.S. National Highway Traffic Safety Administration (NHTSA), which has assigned it Recall Number 20E-018.

This Safety Campaign authorizes certified repair locations to disable the fuel heater, to remove the fuse powering the fuel heater circuit, and to cap and secure the fuel heater wiring harness connector on certain B6.7 CM2350 B121B units.

Action

In order to qualify for repair under this field action, an engine:

will be covered regardless of coverage status, and
must show as OPEN on QuickServe® Online for this field action.

Note : The ESN list is attached for reference.

After verifying that the engine meets the above requirements, perform the following actions:

If a non-disabled fuel heater is currently installed in the fuel filter module and does not show signs of a fuel leak or melted plastic, refer to the Scenario 1 service instructions within Attachment B to disable the fuel heater, to remove the fuse powering the fuel heater circuit, and to cap and secure the fuel heater wiring harness connector using kit part number 5633457.
If a fuel heater is currently installed and shows signs of a fuel leak and/or melted plastic, refer to the Scenario 2 service instructions within Attachment B to install a fuel heater plug and to cap and secure the fuel heater wiring harness connector using kit part number 5579133. 3. If the fuel filter module is damaged, refer to the Scenario 3 service instructions within Attachment B to install a plugged fuel filter module and to cap and secure the fuel heater wiring harness connector using kit part numbers 5661486 and 5633457.
If a fuel heater plug is currently installed, no further repair is needed. Refer to the service instructions within attachment B to confirm that the fuse powering the fuel heater circuit has been removed and that the fuel heater wiring harness connector has been properly capped and secured. Claim ONLY Administrative Time and SRT 17-902 (Campaign/SCR Check) to close the field action.

Material Disposition

Where applicable, materials removed as a result of this field action must be returned to Cummins. Parts flagged via the Cummins Enhanced Parts Return (EPR) process should be returned following the stated instructions. Please return the parts to:

Cummins Service Support Center
910 S. Marr Road, Receiving Location 35
Columbus, IN 47201
Attn: Service Support Center Manager
Email: ssc@cummins.com

Note : Parts covered by the Field Action are to be returned to the Cummins Service Support Center. Please include a copy of the claim paperwork and a material return tag with the returned parts. Include the ESN number, the Campaign #2302, and the claim number on the material return tag. For Cummins returns, record WebCumpas# on the outside of the box. For PACCAR returns, record CRA# or Eztrac#.

Reimbursements

Parts

The following parts are covered under this field action:

Note : Only Customer Down Orders or Warranty Orders will be released for this field action at this time.

Part Number	Quantity	Description
557913300	1	PLUG/ HARNESS CAP (OPTIONAL)
563345700	1	HARNESS CAP ONLY (OPTIONAL)
566148600	1	FLTR MDL WITH PLUG (OPTIONAL)

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.

Note : All SRTs listed are OPTIONAL. Select ONLY the appropriate SRTs for the repair performed. Claim ONLY SRTs 99-007 and Admin if the unit DID require a repair. Only SRT 17-902 and Admin should be claimed if the unit DID NOT require a repair.

Labor Using Applicable Access Code and Time

SRT Code	Description	Time (hrs)
00-90X	Administrative time
17-902	CAMPAIGN CHECK – OPTIONAL
99-007	REMOVE FUSE, DISABLE HEATER OR INSTALL PLUG, CAP HARNESS (QTY 1 ) – OPTIONAL

Travel

Travel is covered under this field action. Towing is covered under this field action. Other Claimables

Consumables are covered under this field action.

Note : Please consolidate all consumables and claim them as one item in Other Claimables titled “CAMPAIGN SUPPLIES”.

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:	Distributor = X
Pay Code:	Dealer = D
Pay Code:	International = I
Failure Code:	WFEHTE

Attachments

Click here to see c2302_esn-list.xlsx

(/service/english/attachments/c2302_esn-list.xlsx)Click here to see c2302_attachment-b.pdf

(/service/english/attachments/c2302_attachment-b.pdf)

Contents

Special Note

The purpose of this campaign is to disable the fuel heater. If a plug is in place rather than a heater, either from completion of TRP 2129, action taken by following TSB190038, or being built with a plug, then no further action is needed at this time.

Verification

Locate the Stage 1 fuel filter head on engine. The engine fuel heater is located on the top right side of the fuel filter head. See Figure 1 below.

Engine fuel heater
Cable tie
Electrical connector

Note: The location in the connector (3) of the red and white wires in Figure 1 above may differ slightly based on previous campaign work done to this engine.

Check the fuel heater to see if there is damage (melting or leaking), similar to Figure 2.
- If engine fuel heater is not damaged or leaking fuel after engine shutdown, and the fuel filter module is not damaged, follow scenario 1.
- If engine fuel heater is damaged, or leaking fuel after engine shutdown, but fuel filter module is not damaged, follow instructions for scenario 2.
- If fuel filter module is damaged, follow instructions for scenario 3.

Figure 2, Damaged Engine Fuel Heater Component and Fuel Leakage.

Parts Needed Table 1, Associated Part Numbers

Part Description	Cummins Part Number
*Scenario 1*: Electrical Plug- See Figure 3	5633457
*Scenario 2*: Engine Fuel Heater Port Plug Kit- See Figure 4	5579133
*Scenario 3*: Fuel Filter Module with plug	5661486

Figure 3, 5633457, KIT, HARNESS INSTALLATION

Figure 4, Part Number 5579133 Contents: Left: Heater Plug and Allen Screws.
Right: Electrical Plug.

Resolution- steps for all scenarios

Remove cable tie that secures the wiring harness to engine fuel heater. See Figure 5.

Unlock connector by moving red tab to the right and disconnecting from engine fuel heater. See Figure 5.
Unplug electrical connector from engine fuel heater and protect the female end of the wiring harness to prevent any damage and/or contamination from occurring by using electrical plug supplied in kit.
Secure fuel heater harness to engine wiring harness using zip ties to prevent damage. See Figure 6.
1. Cable tie part numbers:
  1. Navistar® part number 306132C1
  2. Supplier part number T120R0HSH4

Figure 5, Removing Cable Tie and Installing Electrical Plug Cap

Figure 6, Securing Wiring Harness for Navistar® CE Bus and 1300 FBC.

Remove fuse powering engine fuel heater circuit on chassis. See model specific instructions in Figures 7-9.
Address cold weather fuel gelling issues with chemical treatment (such as Power Service Diesel Fuel Supplement® +Cetane Boost®) to the fuel system.
Disable fuel heater following specific scenario instructions on the following pages.

Navistar® CE Bus and 1300 FBC Fuse and Wire Harness Instruction

Disconnect vehicle battery.
Locate red 50 amp or green 30 amp Maxi Fuse on under hood fuse panel. See Figure 7 below.
Remove fuse cap and discard Maxi Fuse. See Figure 7 below.
Reinstall fuse cap. Do not replace fuse. See Figure 7 below.

Figure 7, Location of Fuse on Navistar® CE Bus and 1300 FBC.

Navistar® Truck / TC Commercial Bus Fuse and Instructions

Remove fuse.

Disconnect vehicle battery
Remove 30 or 40 amp fuse located at 2C cavity. See Figure 8 below.

Figure 8, Location of 30A or 40A Fuse on Navistar® MV/HV/TC.

Location of Fuse on Navistar® DuraStar (4300) / WorkStar (7300) / HC Commercial Bus

Remove fuse.

Disconnect vehicle battery.
Remove Power Distribution Module (PDM) cover, located under the hood on the driver side. See Figure 9 below.
Remove fuse located at 2C cavity. See Figure 9 below.

Figure 9, Location of Fuse on Navistar® DuraStar (4300) / WorkStar (7300) / HC Commercial Bus

Scenario-Specific Instructions

Scenario 1: Engine fuel heater is not damaged, or is not leaking fuel after engine shutdown, and the fuel filter module is not damaged:

Ensure that the fuse is removed and harness is secured, as detailed on pages 4-8.
Without removing the fuel heater from the filter head, disable the on-engine fuel heater by cutting through the connector with a fine-toothed hacksaw blade, die/angle grinder with cut-off wheel, or other rotary/reciprocating tool capable of making clean, smooth cuts. Be careful not to damage nearby components when cutting. Do not use a screwdriver, hammer, bolt cutter, or side cuts. Figure 10 shows the preferred cut location and Figure 11 shows the acceptable area range for the cut. Figure 12 shows a fuel heater with the work completed.

Figure 10: Preferred location to cut

Figure 11: Acceptable cutting range to disable fuel heater.

Figure 12: Fuel Heater shown after cutting complete

Inspect nearby components to ensure that nothing was damaged during the cutting procedure.
Restart engine and check heater area to ensure there is no fuel leakage from the area that was cut or other issues resulting from cutting procedure.
If fuel leakage is seen, refer to instructions in scenario 2.

Scenario 2: Engine fuel heater is damaged, or leaking fuel after engine shutdown, but fuel filter module is not damaged: Replace existing fuel heater and associated components with engine fuel heater plug kit, Part Number 5579133.

Ensure that the fuse is removed and harness is secured, as detailed on pages 4-8.
Remove and discard two allen screws securing engine fuel heater to the fuel filter head with a 5mm hex driver. See Figure 13.
Pull the engine fuel heater straight out of the fuel filter head. Capture any fuel that may leak from the fuel filter. See Figure 13.

Figure 13, Removal of Heating Element.

Clean face of engine fuel heater port with a lint free cloth and inspect for any sharp edges and/or contaminants. Clean if needed.

Lubricate the o-ring on the plug (supplied in kit part number 5579133) with clean diesel fuel and carefully install into the engine fuel heater port, making sure to properly align before installing. See Figure 14.

Use the two allen screws supplied to secure the plug to the fuel filter head and tighten to 11 N-m [ 6.6 ft-lb ]. See Figure 14.

Figure 14, Installation of Heater Port Plug.

Scenario 3: If fuel filter module is damaged

Ensure that the fuse is removed and harness is secured, as detailed on pages 4-8.
Install new fuel filter module, Part Number 5661486.

◦ See B6.7 CM2350 B121B Service Manual, Bulletin 5411223.

A CUMMINS FIELD CAMPAIGN

Please Deliver To: Service Managers and Warranty Decision Makers

FROM: Cummins Global Warranty Administration Communications

Subject: B6.7 Engine-Mounted Fuel Heater Safety Campaign

Number: C2302

Date: 09-Jul-2020

Expires:

01-May-2045 (U.S./Canada)
01-May-2045 (International)

Attention:

U.S. / Canadian Dealers
U.S. / Canadian Distr./Branches and Div. Offices
Worldwide distr./ branches and Div./Reg Offices (Automotive)

This is to revise and replace Campaign 2302, dated 01-May-20. This revision is to:

1 Add Parts ordering narratives.

If additional information is required, please contact your Cummins Warranty Operations Group Leader.

DESCRIPTION:

Cummins has reported this issue to the U.S. National Highway Traffic Safety Administration (NHTSA), which has assigned it Recall Number 20E-018.

ACTION:

In order to qualify for repair under this field action, an engine:

will be covered regardless of coverage status, and
must show as OPEN on QuickServe® Online for this field action.

NOTE: The ESN list is attached for reference.

After verifying that the engine meets the above requirements, perform the following actions:

If a non-disabled fuel heater is currently installed in the fuel filter module and does not show signs of a fuel leak or melted plastic, refer to the Scenario 1 service instructions within Attachment B to disable the fuel heater, to remove the fuse powering the fuel heater circuit, and to cap and secure the fuel heater wiring harness connector using kit part number 5633457.
If a fuel heater is currently installed and shows signs of a fuel leak and/or melted plastic, refer to the Scenario 2 service instructions within Attachment B to install a fuel heater plug and to cap and secure the fuel heater wiring harness connector using kit part number 5579133.
If the fuel filter module is damaged, refer to the Scenario 3 service instructions within Attachment B to install a plugged fuel filter module and to cap and secure the fuel heater wiring harness connector using kit part numbers 5661486 and 5633457.
If a fuel heater plug is currently installed, no further repair is needed. Refer to the service instructions within attachment B to confirm that the fuse powering the fuel heater circuit has been removed and that the fuel heater wiring harness connector has been properly capped and secured. Claim ONLY Administrative Time and SRT 17-902 (Campaign/SCR Check) to close the field action.

MATERIAL DISPOSITION:

Cummins Service Support Center
910 S. Marr Road, Receiving Location 35
Columbus, IN 47201
Attn: Service Support Center Manager
Email: ssc@cummins.com

NOTE: Parts covered by the Field Action are to be returned to the Cummins Service Support Center. Please include a copy of the claim paperwork and a material return tag with the returned parts. Include the ESN number, the Campaign #2302, and the claim number on the material return tag. For Cummins returns, record WebCumpas# on the outside of the box. For PACCAR returns, record CRA# or Eztrac#.

REIMBURSEMENTS:

Parts:

The following parts are covered under this field action:

NOTE: Only Customer Down Orders or Warranty Orders will be released for this field action at this time.

NOTE: Ordering all 3 parts per one ESN#/unit is not required and not allowed. The vast majority (95% or greater) of repairs will only require part number 5633457. Only order one of the other 2 parts if damage is found when performing Scenario 1. Customer Order Management must be given confirmation of damage with the order of either part 5579133 or 5661486. Please state in dealer PO field in Cumpas and BMS “Damage to XX part confirmed”. If confirmation of damage is NOT given, the order will be canceled.

Part Number	Quantity	Description
557913300	1	PLUG/ HARNESS CAP (OPTIONAL, SEE NOTE ABOVE)
563345700	1	HARNESS CAP ONLY (OPTIONAL, SEE NOTE ABOVE))
566148600	1	FLTR MDL WITH PLUG (OPTIONAL, SEE NOTE ABOVE)

NOTE: Please refer to Attachment B for more details around repairs scenarios.

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.

NOTE: All SRTs listed are OPTIONAL. Select ONLY the appropriate SRTs for the repair performed. Claim ONLY SRTs 99-007 and Admin if the unit DID require a repair. Only SRT 17-902 and Admin should be claimed if the unit DID NOT require a repair.

Labor using applicable Access Code and Time:

SRT Code	Description	Time
00-90X	Administrative time
17-902	CAMPAIGN CHECK – OPTIONAL
99-007	REMOVE FUSE, DISABLE HEATER OR INSTALL PLUG, CAP HARNESS (QTY 1 ) – OPTIONAL

Travel:

Travel is covered under this field action. Towing is covered under this field action.

Other Claimables:

Consumables are covered under this field action.

NOTE: Please consolidate all consumables and claim them as one item in Other Claimables titled “CAMPAIGN SUPPLIES”.

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.

Account Code:	65
Pay Code:	Distributor = X
Pay Code:	Dealer = D
Pay Code:	International = I
Failure Code:	WFEHTE

Attachments

c2302_esn-list.xlsxc2302_attachment-b.pdf

* IMPORTANT SAFETY RECALL*

NHTSA Recall No. 20E-018
Cummins Campaign #C2302
Second Notice

November 30, 2020

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 B6.7 diesel engines that were manufactured between December 16, 2015 and March 24, 2020 and equipped with fuel module option FS90301 or FS90453.

This notice applies to your engine(s) listed on the enclosed Engine/Vehicle list.

If your engine was manufactured between December 16, 2015 and February 25, 2019, you received a similar notice regarding NHTSA Recall No. 19E-020 (Cummins Safety Campaign #C2127) pertaining to your engine(s). This recall notice supersedes the prior recall notice; you must have the remedy described in this recall performed on your engine, even if your engine was remedied under the prior recall.

If your engine was manufactured between February 26, 2019 and November 5, 2019, your engine may have had repairs done according to Cummins Campaign #C2128 or ATC2278. This recall notice supersedes actions under those field actions; you must have the remedy described in this recall performed on your engine, even if your engine was remedied under those actions.

If your engine was manufactured between November 6, 2019 and March 24, 2020, this is a new action.

WHY IS A RECALL BEING CONDUCTED?

Fuel module options FS90301 and FS90453 contain an electric fuel heater. Internal electrical heating within the fuel heater may create sufficient heat inside the fuel heater to cause plastic in the fuel heater to melt and potentially catch fire. It may also cause an engine stall. A fire, if undetected and uncontained, presents an increased risk of personal injury. An unexpected engine stall may increase the risk of a crash. If this condition exists, melting of the fuel heater or fuel seepage from around the fuel heater may be visible during a service event, smoke may precede or accompany a fire, or the engine may become increasingly difficult to start.

WHAT ARE WE DOING ABOUT THE PROBLEM?

Cummins has released field Safety Campaign #C2302 “B6.7 Engine-Mounted Fuel Heater Safety Campaign” to correct this condition. This campaign is currently available at Cummins Distributors and Cummins-authorized Warranty Dealers. The remedy will consist of the following: (1) disabling the fuel heater by either installing a plug in place of the fuel heater or otherwise rendering the fuel heater inoperable and (2) removing the fuse supplying electrical power to the fuel heater and installing a cover over the wire harness connector. The repair will be completed free of charge (parts and labor) and most applications will require approximately 30 minutes to complete.

This safety recall addresses the potential safety defect for your engine. However, this repair will disable the fuel heater. Cummins is currently working to determine an appropriate cold weather starting aid for customers that require it. Cummins Distributors and Dealers will be notified when a separate field action is available.

WHAT SHOULD YOU DO?

Contact the nearest Cummins Distributor or authorized Warranty Dealer to arrange to have this campaign performed on your engine. The distributor or dealer will work with you to schedule the best date to complete this repair.

In the meantime, to mitigate the safety risk, Cummins advises you to remove the fuel heater fuse as shown in Figures 1, 2 or 3 below (based on the vehicle).

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 1-800CUMMINS (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 https://www.safercar.gov.

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.

If you are no longer the owner of the engine or vehicle listed in the table, please forward this notice to the new owner or provide the new owner’s contact information to Cummins at cummins.campaign.administration@cummins.com so that we can notify them of this recall.

Cummins is taking this action in the interest of safety and satisfaction with our products. We apologize for any inconvenience and thank you for your attention to this matter.

Sincerely,

Campaign Administrator Cummins Inc.

Navistar® CE Bus and 1300 FBC Fuse Removal Instructions (Reference Figure 1 below)

Disconnect vehicle battery.
Locate red 50 Amp or green 30 Amp Maxi Fuse on under hood fuse panel.
Remove fuse cap and discard red or green Maxi Fuse.
Reinstall fuse cap. Do not replace fuse.
Reconnect vehicle battery.

Navistar® MV, HV and TC Commercial Bus (some DuraStar (4300)/WorkStar (7300) Fuse Removal Instructions (Reference Figure 2 below)

Disconnect vehicle battery.
Remove 30 or 40 amp fuse located at 2C cavity.
Reconnect vehicle battery.

Navistar® DuraStar (4300) / WorkStar (7300) / HC Commercial Bus Fuse Removal Instructions (Reference Figure 3 below)

Disconnect vehicle battery.
Remove Power Distribution Module (PDM) cover, located under the hood on the driver side of the vehicle.
Remove fuse located at cavity 2C.
Reconnect vehicle battery.

*** IMPORTANT SAFETY RECALL***
NHTSA Recall No. 20E-018
Cummins Campaign #C2302

May 29, 2020

Dear Cummins Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

This notice applies to your engine(s) listed on the enclosed Engine/Vehicle list.

If your engine was manufactured between November 6, 2019 and March 24, 2020, this is a new action.

WHY IS A RECALL BEING CONDUCTED?

WHAT ARE WE DOING ABOUT THE PROBLEM?

Cummins has released field Safety Campaign #C2302 “B6.7 Engine-Mounted Fuel Heater Safety Campaign” to correct this condition. This campaign is currently available at Cummins Distributors and Cummin s-authorized Warranty Dealers. The remedy will consist of the following: (1) disabling the fuel heater by either installing a plug in place of the fuel heater or otherwise rendering the fuel heater inoperable and (2) removing the fuse supplying electrical power to the fuel heater and installing a cover over the wire harness connector. The repair will be completed free of charge (parts and labor) and most applications will require approximately 30 minutes to complete.