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July 14, 2022 NHTSA CAMPAIGN NUMBER: 22V506000
Improperly Grounded Air Compressor Housing
An improperly grounded air compressor can cause electric shock, increasing the risk of injury.
NHTSA Campaign Number: 22V506
Manufacturer Blue Bird Body Company
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 1
Summary
Blue Bird Body Company (Blue Bird) is recalling one 2022 All American transit bus equipped with a Cummins PD7000 Electric Drivetrain containing an electric air compressor. The air compressor housing is improperly grounded, causing electrical voltage greater than 50V AC during operation.
Remedy
Dealers will install an electrical ground strap between the compressor motor housing and vehicle chassis, free of charge. The interim owner notification letter was mailed on September 1, 2022. Remedy parts are expected to become available mid-February 2023. Owners may contact Blue Bird’s customer service at 1-478-822-2242. Blue Bird’s number for this recall is R22BY-NSB.
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.
Campaign Number: C2619
BES PD7000 Air Compressor Grounding Safety Campaign
Chronology :
April 21, 2022: A Cummins employee experienced a mild electric shock, when he touched the air compressor motor housing at a Cummins facility.
April 21 through May 11, 2022: Cummins conducted an investigation to understand the cause of the issue.
During the investigation, the voltage between the air compressor housing and vehicle chassis for the incident unit was measured as 110 V to 130V AC. Testing was conducted on the two configurations of air compressor and inverter assemblies to understand the ground paths and to verify the missing ground.
May 11 through June 1, 2022: A Cummins Product Safety Hazard Analysis was conducted. Testing was completed on the current production air compressor to confirm that it does not have this condition.
June 1 through June 28, 2022: Cummins escalated the issue through its Product Safety Defect Determination process.
June 28, 2022: 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 electrical shock (other than the Cummins employee on April 21, 2022 or injuries due to this condition.
July 12, 2022: Blue Bird Corporation was notified by Cummins of the Air Compressor Safety Recall Campaign.
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
BLUE BIRD | ALL AMERICAN | 2022 |
7 Associated Documents
Defect Notice 573 Report
RCLRPT-22V506-3421.PDF 214.382KB
Recall Acknowledgement
RCAK-22V506-6720.pdf 645.829KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-22V506-8117.pdf 93.958KB
Recall 573 Report – 1/23/23
RCLRPT-22V506-7771.PDF 214.498KB
Remedy Instructions and TSB
RCRIT-22V506-5489.pdf 2171.291KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V506-6034.pdf 99.162KB
Recall Quarterly Report #1, 2023-1
RCLQRT-22V506-6157.PDF 211.14KB
Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V506&docType=RCL
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SEOCONTENT-START
Cummins Inc. Box 3005 Columbus, IN 47202 – 3005 USA Mail Code: 40911 Phone: 1 800 CUMMINS care cummins.com *** IMPORTANT SAFETY RECALL*** NHTSA Recall No. 22E-054 Interim Recall Notice September 2, 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 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(s) listed on the enclosed table. WHAT IS THE PROBLEM? The air compressor housing is not properly grounded; as a consequence, the air compressor housing may experience electrical voltage greater than 50V AC during air compressor operation. This condition may lead to an electric shock for any person (in particular, service personnel) touching the air compressor housing while the air compressor is operating. This issue does not present a hazard to occupants of a vehicle during operation. WHAT WILL CUMMINS DO? Cummins will correct this condition by installing a ground strap between the air compressor motor housing and the vehicle chassis. Cummins is currently procuring the parts for this remedy. 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? In the meantime, Cummins advises operators and service personnel to ensure the air compressor is not operating by turning off the vehicle keyswitch before opening the access door (if so equipped) or before touching the air compressor. 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 Cummins Inc. Box 3005 Columbus, IN 47202 – 3005 USA Mail Code: 40911 Phone: 1 800 CUMMINS care cummins.com 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. 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 vehicle(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 new vehicle or equipment covered by this recall notice under a sale or lease until the defect has been remedied. 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.
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2/1/23, 9:08 AM BES PD7000 Air Compressor Grounding Safety Campaign https://quickserve.cummins.com/qs3/pubsys2/xml/en/campaign/2026/c2619.html 1/3 Warranty Field Campaign Campaign Number: c2619 Revision: BES PD7000 Air Compressor Grounding Safety Campaign Released Date: 26-Jan- 2023 Expiration Date (U.S. and Canada): 31-Jan-2053 Expiration Date (International): 31-Jan- 2053 Attention If additional information is required, please contact your Cummins Warranty Operations Group Leader. Description Action Worldwide distr./ branches and Div./Reg Offices U.S. / Canadian Dealers U.S. / Canadian Distr./Branches and Div. Offices (Automotive) This Safety Campaign is being issued to install grounding straps (PN 6301390) between the High Voltage Air Compressor Motor and the chassis on all BES CM0904 EV104B and BES CM2450 EV105B products. In order to qualify for repair under this field action, an air compressor: 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: Note : Please refer to Attachment B for detailed repair instructions. 1. Perform Lockout Tagout then install grounding strap between High Voltage Air Compressor and mounting location on High Voltage Air Compressor Inverter. 2. File a claim for one or more SSNs updated at the same time. 2/1/23, 9:08 AM BES PD7000 Air Compressor Grounding Safety Campaign Material Disposition There are no materials to be removed in this field action. Reimbursements Parts The following parts are covered under this field action: Part Number 010077200 563643400 630139000 Quantity 1 1 1 Description NUT,LCK SCR,CAP SRP,GND 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 Air Compressor – Remove 33-005 33-01S 99-00C Travel and Install – BES CM0904 EV104B (OPTIONAL) Air Compressor – Remove and Install – BES CM2450 EV105B (OPTIONAL) GROUNDING STRAP INSTALLATION (QTY 1) Travel is covered under this field action. Towing is covered under this field action. Other Claimables Consumables are covered under this field action. Claim Instructions https://quickserve.cummins.com/qs3/pubsys2/xml/en/campaign/2026/c2619.html 2/3 2/1/23, 9:08 AM BES PD7000 Air Compressor Grounding Safety Campaign 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: WCAGSA Attachments Click here to see c2619_ssn-list.xlsx (/service/english/attachments/c2619_ssn-list.xlsx) Click here to see c2619_attachment-b.pdf (/service/english/attachments/c2619_attachment-b.pdf) All Engine Family Design Application All Fuel System Market Application Document History Date Details Document Created; 26-Jan-2023 Last Modified: 26-Jan-2023 https://quickserve.cummins.com/qs3/pubsys2/xml/en/campaign/2026/c2619.html 3/3 C2619 – Attachment B BES PD7000 Air Compressor Grounding Safety Campaign Installing Grounding Strap On Air Compressor Overview 2A 1. Perform LockOut TagOut (LOTO) on the unit following Safe Service Procedure. Refer to the service manual link below. Both models use the same procedure. https://quickserve.cummins.com/qs3/service/suite/xml/en/purpose/10/10- 24-1584.html#s32239 2. Install grounding strap (CMI PN 6301390) to Air compressor assembly. 2A – Attach one side to the pre-existing hole on the air compressor oil dipstick bracket. – Torque: 27 N∙m [239 in-lb] 2B – Attach one side to the air compressor inverter mounting location. 2B – Torque: 27 N∙m [239 in-lb] 3. Ensure grounding strap is not rubbing against any cables or hoses (caution areas shown on next slide) Some buses may require the Air compressor assembly to be lowered or removed from the chassis to complete step #2. If necessary, refer to service manual instructions (linked below) to remove, then reinstall the air compressor assembly. Both models use the same procedure https://quickserve.cummins.com/qs3/service/suite/xml/en/purpose/10/10-29- 3206.html Internal Use Only 2 Step 3 – Ensure grounding strap is not rubbing against any cables or hoses Proper Routing Improper Routing Potential spots for rubbing to watch out for Rubbing on hose Critical to ensure there is no rubbing on the HV cable Rubbing on wires Internal Use Only 3 44
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Cummins Inc. Box 3005 Columbus, IN 47202 – 3005 USA Mail Code: 40911 Phone: 1 800 CUMMINS care cummins.com *** IMPORTANT SAFETY RECALL*** NHTSA Recall No. 22E-054 Cummins Campaign #C2619 February 3, 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 PowerDrive™ electric drivetrain systems that were manufactured between June 1, 2018 and March 8, 2021. Cummins previously mailed you an interim notice advising you of this recall and informing you that you would receive this second notice when the remedy is available. This notice applies to the PowerDrive electric drivetrain systems in your vehicle(s) listed on the enclosed table. WHY IS A RECALL BEING CONDUCTED? The air compressor housing is not properly grounded; as a consequence, the air compressor housing may experience electrical voltage greater than 50V AC during air compressor operation. This condition may lead to an electric shock for any person (in particular, service personnel) touching the air compressor housing while the air compressor is operating. This issue does not present a hazard to occupants of a vehicle during operation. WHAT ARE WE DOING ABOUT THE PROBLEM? Cummins has released field Safety Campaign #C2619 BES PD7000 Air Compressor Grounding Safety Campaign to correct this condition. The remedy is to install a ground strap between the air compressor motor housing and the vehicle chassis. Repair parts are currently available at Cummins Distributors and authorized Warranty Dealers. The repair will be completed free of charge (parts and labor) and most applications will require approximately 3 ½ hours to complete. Cummins Inc. Box 3005 Columbus, IN 47202 – 3005 USA Mail Code: 40911 Phone: 1 800 CUMMINS care cummins.com WHAT SHOULD YOU DO? Contact the nearest Cummins Distributor or authorized Warranty Dealer to arrange to have this campaign performed on your vehicle. The distributor or dealer will work with you to schedule the best date to complete the repair. In the meantime, Cummins advises operators and service personnel to ensure the air compressor is not operating by turning off the vehicle keyswitch before opening the access door (if so equipped) or before touching the air compressor. 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. 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 vehicle(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 new vehicle or equipment covered by this recall notice under a sale or lease until the defect has been remedied. 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.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-506 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Blue Bird Body Company Submission Date : JAN 23, 2023 NHTSA Recall No. : 22V-506 Manufacturer Recall No. : R22BY-NSB Manufacturer Information : Manufacturer Name : Blue Bird Body Company Address : P.O. Box 937 402 Blue Bird Boulevard Fort Valley GA 31030 Company phone : 478-822-2242 Population : Number of potentially involved : 1 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 Blue Bird All American Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : The subject Electric Drivetrain contains an electric air compressor to supply compressed air to the vehicle. These systems were sold as original equipment for installation in certain school buses and as original or upfit equipment for installation in certain medium duty trucks and terminal tractors. This recall consists of the entire population of PD7000 systems built prior to implementation of a new air compressor. Production Dates : APR 06, 2022 – APR 06, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The air compressor housing on these units is not properly grounded. As a consequence, the air compressor housing may experience an electrical voltage potential greater than 50V AC during air compressor operation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : This condition may lead to an increased risk of injury from electric shock for any person (in particular, service personnel) touching the air compressor housing assembly while the air compressor is operating. Description of the Cause : The cause is missing electrical grounding of the air compressor housing with respect to the vehicle chassis. Identification of Any Warning that can Occur : None Part 573 Safety Recall Report 22V-506 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : Compressor, Air (Cummins) Component Description : Electrically Driven Air Compressor (Cummins) Component Part Number : 5611745 (Cummins) Supplier Identification : Component Manufacturer Name : Cummin, Incorporated Address : 500 Jackson Street Columbus Indiana 47201 Country : United States Chronology : April 21, 2022: A Cummins employee experienced a mild electric shock, when he touched the air compressor motor housing at a Cummins facility. April 21 through May 11, 2022: Cummins conducted an investigation to understand the cause of the issue. During the investigation, the voltage between the air compressor housing and vehicle chassis for the incident unit was measured as 110 V to 130V AC. Testing was conducted on the two configurations of air compressor and inverter assemblies to understand the ground paths and to verify the missing ground. May 11 through June 1, 2022: A Cummins Product Safety Hazard Analysis was conducted. Testing was completed on the current production air compressor to confirm that it does not have this condition. June 1 through June 28, 2022: Cummins escalated the issue through its Product Safety Defect Determination process. June 28, 2022: 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 electrical shock (other than the Cummins employee on April 21, 2022 or injuries due to this condition. July 12, 2022: Blue Bird Corporation was notified by Cummins of the Air Compressor Safety Recall Campaign. Part 573 Safety Recall Report 22V-506 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : An electrical ground strap will be installed between the air compressor motor housing and the vehicle chassis. 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 reimburse the cost of the repair related to this recall at no cost to the Dealer or to the vehicle owner. How Remedy Component Differs from Recalled Component : The air compressor with the remedy ground strap installed will be visibly different than the air compressor without the ground strap. Identify How/When Recall Condition was Corrected in Production : For reasons unrelated to this condition, units manufactured on and after 4/19/2022 are equipped with a new air compressor (P/N 5678863) in which the air compressor and electrical inverter are integrated into a single assembly that is collectively electrically grounded and does not have this condition. Recall Schedule : Description of Recall Schedule : Dealer and Owner Notifications are to be issued on or before September 2, 2022. Parts availability undetermined at this time. Cummins will reimburse the labor cost of the repair related to this recall at no cost to the Dealer or to the vehicle owner. Cummins expects the remedy to be available and published to Cummins’ service network mid- February 2023 and will mail owner letters shortly after the campaign is released to the field. Planned Dealer Notification Date : FEB 06, 2023 – FEB 06, 2023 Planned Owner Notification Date : FEB 06, 2023 – FEB 06, 2023 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-506 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Blue Bird Body Company Submission Date : JUL 14, 2022 NHTSA Recall No. : 22V-506 Manufacturer Recall No. : R22BY-NSB Manufacturer Information : Manufacturer Name : Blue Bird Body Company Address : P.O. Box 937 402 Blue Bird Boulevard Fort Valley GA 31030 Company phone : 478-822-2242 Population : Number of potentially involved : 1 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 Blue Bird All American Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : The subject Electric Drivetrain contains an electric air compressor to supply compressed air to the vehicle. These systems were sold as original equipment for installation in certain school buses and as original or upfit equipment for installation in certain medium duty trucks and terminal tractors. This recall consists of the entire population of PD7000 systems built prior to implementation of a new air compressor. Production Dates : APR 06, 2022 – APR 06, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The air compressor housing on these units is not properly grounded. As a consequence, the air compressor housing may experience an electrical voltage potential greater than 50V AC during air compressor operation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : This condition may lead to an increased risk of injury from electric shock for any person (in particular, service personnel) touching the air compressor housing assembly while the air compressor is operating. Description of the Cause : The cause is missing electrical grounding of the air compressor housing with respect to the vehicle chassis. Identification of Any Warning that can Occur : None Part 573 Safety Recall Report 22V-506 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : Compressor, Air (Cummins) Component Description : Electrically Driven Air Compressor (Cummins) Component Part Number : 5611745 (Cummins) Supplier Identification : Component Manufacturer Name : Cummin, Incorporated Address : 500 Jackson Street Columbus Indiana 47201 Country : United States Chronology : April 21, 2022: A Cummins employee experienced a mild electric shock, when he touched the air compressor motor housing at a Cummins facility. April 21 through May 11, 2022: Cummins conducted an investigation to understand the cause of the issue. During the investigation, the voltage between the air compressor housing and vehicle chassis for the incident unit was measured as 110 V to 130V AC. Testing was conducted on the two configurations of air compressor and inverter assemblies to understand the ground paths and to verify the missing ground. May 11 through June 1, 2022: A Cummins Product Safety Hazard Analysis was conducted. Testing was completed on the current production air compressor to confirm that it does not have this condition. June 1 through June 28, 2022: Cummins escalated the issue through its Product Safety Defect Determination process. June 28, 2022: 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 electrical shock (other than the Cummins employee on April 21, 2022 or injuries due to this condition. July 12, 2022: Blue Bird Corporation was notified by Cummins of the Air Compressor Safety Recall Campaign. Part 573 Safety Recall Report 22V-506 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : An electrical ground strap will be installed between the air compressor motor housing and the vehicle chassis. 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 reimburse the cost of the repair related to this recall at no cost to the Dealer or to the vehicle owner. How Remedy Component Differs from Recalled Component : The air compressor with the remedy ground strap installed will be visibly different than the air compressor without the ground strap. Identify How/When Recall Condition was Corrected in Production : For reasons unrelated to this condition, units manufactured on and after 4/19/2022 are equipped with a new air compressor (P/N 5678863) in which the air compressor and electrical inverter are integrated into a single assembly that is collectively electrically grounded and does not have this condition. Recall Schedule : Description of Recall Schedule : Dealer and Owner Notifications are to be issued on or before September 2, 2022. Parts availability undetermined at this time. Cummins will reimburse the labor cost of the repair related to this recall at no cost to the Dealer or to the vehicle owner. Planned Dealer Notification Date : SEP 02, 2022 – SEP 02, 2022 Planned Owner Notification Date : SEP 02, 2022 – SEP 02, 2022 * NR – Not Reported
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