21E024 Cummins Electric Drivetrain PD7000 Isolation Faults Can Go Undetected

March 30, 2021 NHTSA CAMPAIGN NUMBER: 21E024000

Isolation Faults Can Go Undetected in Drivetrain

An undetected high voltage isolation can expose service personnel to high voltage, increasing the risk of injury.

 

NHTSA Campaign Number: 21E024

Manufacturer CumminseBay logo, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 333

 

Summary

CumminseBay logo, Inc. (CumminseBay logo) is recalling certain Electric Drivetrain part number PD7000. The electric drive train cannot detect isolation faults when the high voltage contactors are closed.

 

Remedy

CumminseBay logo will notify owners, and dealers will update the Vehicle Control Unit software or install a different combination of High Voltage Power Distribution Unit hardware, free of charge. Owner letters were mailed October 25, 2021. Owners may contact CumminseBay logo customer service at 1-800-286-6467.

 

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: c2450Revision:Released Date: 30-Sep2021
BES CM0904 EV104B V2G Isometer Safety Campaign for DCFC UnitsExpiration Date (U.S. and Canada): 30-Sep-2051
Expiration Date (InternationaleBay logo): 30-Sep2051

 

Attention

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

 

Description

This Safety Campaign is being issued to recalibrate the System Control Module (SCM), Battery Management System (BMS), and to connect the Isometer on certain BES CM0904 EV104B V2G products.

 

Action

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.

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

  1. A tool kit is provided to perform this campaign. To obtain a kit please contact CumminseBay logo Care for assistance, 1-800-CUMMINSeBay logo.
  2. Download the latest calibrations for the SCM (BL_3_0_0_9) and BMS (194003). Technical Support is required for the SCM calibration download, please call 1-800-CUMMINSeBay logo.
    1. Ensure that the Isometer is trimmed on.
    2. Ensure that the Coolant Level Sensor is trimmed on.
    3. Ensure that the Charge Control Unit Serials are entered correctly.
  3. If FC124 becomes active, the Isometer Wiring Harness may be disconnected, reconnect Isometer per appropriate Service Manual.
  4. File one claim for one or more SSNs updated at the same time.

 

Material Disposition

There are no materials involved in the field action.

 

Reimbursements

Parts

There are no parts covered 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 CodeDescriptionTime (hrs)
00-90XAdministrative time
31-00YPack Management Unit – Calibrate (CMI)
31-00ZHigh Voltage BatteryeBay logo Management Controller – Calibrate (CMI)
32-00VHigh Voltage DC Junction Box – Remove and Install – BES CM0904 EV104B
99-00ASCM RECAL AND ISOMETER CONNECTION TO COMPLETE THE CALIBRATION (QTY 3 – 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 : 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.

 

Claim Instructions

For CumminseBay logo 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 CumminseBay logo Distributor.

Claim Codes
DescriptionCode
Account Code:65
Pay Code:North America Distributor = X
Pay Code:North America Dealer = D
Pay Code:InternationaleBay logo Distributor = I
Pay Code:InternationaleBay logo Dealer = R
Failure Code:WBJISA

 

Attachments

Click here to see c2450_ssn-list.xlsx

(/service/english/attachments/c2450_ssn-list.xlsx)

Engine FamilyFuel System
Design ApplicationMarket Application
AllAll

 

Document History

DateDetails
Document Creation; 30-Sep-2021

 

Last Modified: 30-Sep-2021

 


*** IMPORTANT SAFETY RECALL***
NHTSA Recall No. 21E-024
Interim Recall Notice

 

May 22, 2021

 

Dear CumminseBay logo Customer:

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.  CumminseBay logo Inc. has decided that a defect which relates to motor vehicle safety exists in certain CumminseBay logo PowerDrive™ electric drivetrain systems that were manufactured between June 1, 2018 and March 8, 2021.

 

This notice applies to the PowerDrive electric drivetrain systems in your vehicle listed on the enclosed table.

 

WHAT IS THE PROBLEM?

The subject electric drivetrain systems, as originally designed, did not include continuous isolation measurement capability to detect isolation faults in the system (between high voltage components and vehicle chassis ground) when the high voltage contactors are closed.

 

If a high voltage isolation fault is not detected and service personnel do not follow prescribed service procedures, they may be exposed to high voltage, increasing the risk of electrical shock.  This issue does not present a hazard to occupants of a vehicle during operation.

 

WHAT WILL CUMMINSeBay logo DO?

CumminseBay logo is currently developing the permanent remedy for this issue.  You will receive a second notification to inform you when the final remedy is available and to provide instructions to schedule the recall for your PowerDrive system.

 

WHAT SHOULD YOU DO?

No action is necessary until you receive a second notification from CumminseBay logo.

 

If you have questions or concerns about this recall, please contact your local CumminseBay logo Distributor or authorized warranty dealer. You may also contact CumminseBay logo Care at 1-800- CUMMINSeBay logo (1-800286-6467) 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 CumminseBay logo 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 vehicle listed on the enclosed table, please forward this notice to the new owner or provide the new owner’s contact information to CumminseBay logo 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 new vehicle or equipment covered by this recall notice under a sale or lease until the defect has been remedied.

 

CumminseBay logo 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 CumminseBay logo Inc.


*** IMPORTANT SAFETY RECALL***
NHTSA Recall No. 21E-033
Interim Recall Notice

 

May 22, 2021

 

Dear CumminseBay logo Customer:

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.  CumminseBay logo Inc. has decided that a defect which relates to motor vehicle safety exists in certain CumminseBay logo PowerDrive™ electric drivetrain systems that were manufactured between June 1, 2018 and February 23, 2021.

 

This notice applies to the PowerDrive electric drivetrain systems in your vehicle listed on the enclosed table.

 

WHAT IS THE PROBLEM?

The subject electric drivetrain systems may experience a condition that results in the loss of electrically assisted power steeringPower steering functionality is restored after a key switch recycle.

 

In the event of loss of power steering assist, manual steering functionality is retained but would require increased steering effort, particularly at lower speeds, increasing the risk of a crash.

 

WHAT WILL CUMMINSeBay logo DO?

CumminseBay logo is currently developing the permanent remedy for this issue.  You will receive a second notification to inform you when the final remedy is available and to provide instructions to schedule the recall for your PowerDrive system.

 

WHAT SHOULD YOU DO?

No action is necessary until you receive a second notification from CumminseBay logo.

 

If you have questions or concerns about this recall, please contact your local CumminseBay logo Distributor or authorized warranty dealer. You may also contact CumminseBay logo Care at 1-800- CUMMINSeBay logo (1-800286-6467), 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 CumminseBay logo 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 vehicle listed on the enclosed table, please forward this notice to the new owner or provide the new owner’s contact information to CumminseBay logo 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.

 

CumminseBay logo 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 CumminseBay logo Inc.

 


*** IMPORTANT SAFETY RECALL ***
NHTSA Recall No. 21E-024

 

April 6, 2021

 

Blue Bird Corporation
3920 Arkwright Road, Suite 200
Macon, Georgia 31210

 

Dear CumminseBay logo OEM Customer:

 

We are writing to inform you that CumminseBay logo Inc. has determined that a safety-related defect exists in certain PD7000 Electric Drivetrains that were manufactured between June 1, 2018 and March 8, 2021.  CumminseBay logo has initiated a recall of the subject systems.  Our records indicate that some of these systems have been shipped to you.

 

A copy of CumminseBay logo’ initial Part 573 Defect Notification report is enclosed.  This notification was submitted to the National Highway Traffic Safety Administration (NHTSA) on March 30, 2021.  As more fully described in the Defect Notification, the Electric Drivetrain systems, as originally designed, did not include continuous isolation measurement capability to detect isolation faults in the system (between high voltage components and vehicle chassis ground) when the high voltage contactors are closed.  If a high voltage isolation fault is not detected and service personnel do not follow prescribed service procedures, they may be exposed to high voltage, increasing the risk of electrical shock.

 

Enclosed is a list of the affected engines that our records indicate were shipped to your plants.  For systems 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.  CumminseBay logo will conduct the recall, including notifying owners pursuant to 49 CFR Part 577, performing the remedy, and submitting quarterly status reports to NHTSA. CumminseBay logo is requesting that you provide the associated vehicle model identification, VINs and owner contact information to facilitate owner notification.  Please work with your CumminseBay logo account team leader to ensure that the requested information is provided to CumminseBay logo as soon as possible.

 

For engines/vehicles that are still in your inventory, please contact Gerardo Leal Villarreal on 812-341-5637 to arrange for repairs, as necessary.  Please note that Federal law prohibits delivery of these systems, or vehicles equipped with these systems, under a sale or lease until this condition has been remedied.

 

CumminseBay logo will conduct a safety campaign to update the systems to provide continuous isolation measurement capability when the contactors are closed.

 

CumminseBay logo 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,

 

Business Development Manager – Electrified Power
CumminseBay logo Inc.

Enclosures:

1. CumminseBay logo Part 573 Defect Notification
2. List of Electric Drivetrain systems

 


*** IMPORTANT SAFETY RECALL***
NHTSA Recall No. 21E-024
CumminseBay logo Campaign #C2450

 

October 25, 2021

 

Dear CumminseBay logo Customer:

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.  CumminseBay logo Inc. has decided that a defect which relates to motor vehicle safety exists in certain CumminseBay logo PowerDrive™ electric drivetrain systems that were manufactured between May 14, 2020 and March 8, 2021.

 

This notice applies to the PowerDrive electric drivetrain systems in your vehicle listed on the enclosed table.

 

You previously received a letter informing you of this recall and informing you that CumminseBay logo was developing a remedy. A remedy is now available for your vehicle.

 

WHAT IS THE PROBLEM?

The subject electric drivetrain systems, as originally designed, did not include continuous isolation measurement capability to detect isolation faults in the system (between high voltage components and vehicle chassis ground) when the high voltage contactors are closed.

If a high voltage isolation fault is not detected and service personnel do not follow prescribed service procedures, they may be exposed to high voltage, increasing the risk of electrical shock.  This issue does not present a hazard to occupants of a vehicle during operation.

 

WHAT ARE WE DOING ABOUT THE PROBLEM? 

CumminseBay logo has released field Safety Campaign #C2450 “BES CM0904 EV104B V2G Isometer Safety Campaign” to correct this condition by updating hardware and software in the drivetrain system. This campaign is currently available at CumminseBay logo Distributors and authorized Warranty Dealers. The repair will be completed free of charge and most applications will require approximately 5 hours to complete.

 

WHAT SHOULD YOU DO?

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

If you have questions or concerns about this recall, please contact your local CumminseBay logo Distributor or authorized warranty dealer. You may also contact CumminseBay logo Care at 1-800- CUMMINSeBay logo (1-800286-6467) 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 CumminseBay logo 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 vehicle listed on the enclosed table, please forward this notice to the new owner or provide the new owner’s contact information to CumminseBay logo 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 new vehicle or equipment covered by this recall notice under a sale or lease until the defect has been remedied.

 

CumminseBay logo 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
CumminseBay logo Inc.

 

CumminseBay logo Inc.
Box 3005
Columbus, IN 47202 – 3005 USA
Mail Code: 40911
Phone: 1 800 CUMMINSeBay logo
care.cummins.com

 



1 Affected Product

Equipment

BRANDPART NO.PRODUCTION DATES
CUMMINSeBay logoPD7000

 


10 Associated Documents

Recall 573 Report – Amendment 1

RCLRPT-21E024-1370.PDF 215.706KB

 


Manufacturer Notices(to Dealers,etc)

RCMN-21E024-3737.pdf 153.964KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21E024-4372.pdf 591.807KB

 


Defect Notice 573 Report

RCLRPT-21E024-7456.PDF 215.439KB

 


Recall Acknowledgement

RCAK-21E024-5200.pdf 646.375KB

 


Recall 573 Report – Amendment 2

RCLRPT-21E024-4723.PDF 216.138KB

 


Recall Quarterly Report #1, 2021-4

RCLQRT-21E024-2959.PDF 211.122KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21E024-0533.pdf 156.31KB

 


Recall 573 Report – 1/12/2022

RCLRPT-21E024-2557.PDF 216.136KB

 


Manufacturer Notices(to Dealers,etc)

RCMN-21E024-2737.pdf 81.287KB

 


Latest Recalls Documents

 


 

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