Recall 23-439 Fuel Station Controller May Fail – 2021-2023 Keystone Carbon, Fuzion, Impact, & Raptor Travel Trailers

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February 15, 2023 NHTSA CAMPAIGN NUMBER: 23V082000

Fuel Station Controller May Fail

A failure of the fuel station controller increases the risk of a fire.

 

NHTSA Campaign Number: 23V082000

Manufacturer Keystone RV Company

Components FUEL SYSTEM, GASOLINE, EQUIPMENT

Potential Number of Units Affected 5,564

 

Summary

Keystone RV Company (Keystone) is recalling certain 2021-2023 Carbon, Fuzion, Impact, and Raptor travel trailers. The fuel station controller may fail.

 

Remedy

Dealers will inspect the circuit protection and install a 15-amp fuse and a box to protect the fuel station controller, free of charge. Owner notification letters were mailed April 5, 2023. Owners may contact Keystone customer service at 1-866-425-4369. Keystone’s number for this recall is 23-439.

 

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.

 


3/28/23

Keystone RV Company
SAFETY ADVISORY # 23-439
Fuel Pump Controller

Keystone is conducting a voluntary RECALL notification campaign in accordance with the National Highway Transportation and Safety Act. It has been decided that the vehicles in the recall population have a fuel station controller that may fail under certain circumstances. In the case of some failures, an increased risk of fire has been shown to exist.

 

Models Included:

Year Model Serial Number Ranges
2021

2022

2023

Carbon – All Models MR805871 – MR805956

NR805000 – NR805814

PR805000 – PR805178

2021

2022

2023

Fuzion – All Models MF811355 – MF811755

NF810000 – NF811225

PF810000 – PF810318

2021

2022

2023

Impact – All Models MF815701 – MF815859

NF815000 – NF815638

PF815000 – PF815189

2021

2022

2023

Raptor – All Models MR801550 – MR801678

NR800000 – NR801106

PR800000 – PR800313

 

Parts Required:  1 – KRV # 270590 – Box – Drain Cover – 7.5″ x 12″ x 2.75″ (This part may be ordered in bulk without a VIN)

2 – Black #8 x 1” screws (purchased locally)

Parts When Needed:   1 – KRV # 696343 – Fuse – Holder – 15 Amp – 10 Ga – W/P – w/15 Amp Fuse – Optifuse – LPR-03BL – 10BL – 15A – DC – Blue (This part may be ordered in bulk without a VIN) (This part can be obtained locally)
1 – Dual Tank Controller KRV # 701368 Fuel Station – COntroller – Carb/EPA Compliant – FLAT – (E/INT2S) – Replaces Krv 681575
1 – Single Tank Controller KRV # 701373 Fuel Station – Controller – Carb/EPA Compliant – FLAT – (E/I) – Single System – Replaces Krv 688169,693217,697535

2 – Wire connectors, if needed (purchased locally)

Tools Required: – Screw gun – Wire cutter/crimpers – Drill – 1/8” Drill bit – Foam gun

 

This Safety Advisory requires a Pre-Authorization & Photograph

Note – Check serial number on Key Express to verify the campaign is open. Some vehicles were repaired before they left Keystone.

 

When performing warranty or recall service, please make certain that appropriate Personal Protective Equipment (PPE) is used.

The remedy is to protect the fuel pump controller from the elements of weather by installing a plastic cover on the back side of the skirt metal, and to make sure the circuit is protected by a 15 amp ATC fuse at the power source. If the circuit is not protected by a 15 amp fuse add an inline fuse like KRV# 696343- Fuse – Holder – 15 Amp – 10 Ga – W/P – w/15 Amp Fuse – Optifuse – LPR-03BL – 10BL – 15A – DC – Blue.

 

REPAIR INSTRUCTIONS

Step 1

Locate the trailer on a level, flat, hard surface. Chock the wheels.

 

Step 2

Locate the fuel pump controller at the rear off door side of the unit, close to the fuel station. Make sure that the back of the controller is clean, free of road debris, and dirt. Inspect the back of the controller for damage or excessive corrosion, replace if necessary. See parts listed above for reference. Pictures of the controller will be required for review.

 

Step 3

Obtain KRV # 270590 – Box – Drain Cover – 7.5″ x 12″ x 2.75″ (cover). Measure between the bottom of the metal skirting and the floor. See Figure 1. Cut the cover from 12” down to 8” or 9” depending on the model. There needs to be enough room between the main floor and the top of the cover for wiring to enter. Drill at least two holes in the bottom of the cover for drainage. See Figure 2.

 

Step 4

Remove the bottom two screws from the face of the fuel pump controller and center the cover over the back side of the fuel pump controller. Reinstall the bottom two screws into the mounting flange of the cover protecting the back side of the fuel pump controller. See figure 2. Using a 1/8” drill bit, place a hole in the mounting flange about ¾ of the way up on each side of the box into the metal skirting. If there are safety stickers mounted on the fender skirt, try to go above or below them. If you only have access to the mounting flange on one side, drill a hole about ¾ of the way up on that side. Go to the outside of the metal skirting and drill the second hole approximately 7” perpendicular to the first hole to hit the other flange. Add a 1” screw into both of the drilled holes. See Figure 3.

 

Step 5

Using expandable foam, seal the top of the plastic cover covering the back side of the controller as seen in Figure 2.

 

Step 6

Check wiring for proper circuit protection at 12VDC mini breakers, these are located close to the battery. The fuel controller must be protected by a 15 amp ATC blade fuse. Using the figures below check all circuits coming off the mini breakers for proper protection. Circuit protection may be found in one of the following arrangements:

  • Attached to a mini breaker inside a 12VDC distribution panel within a couple of feet of the battery to an accessory fuse, make sure the fuse is a 15 amp ATC blade fuse. If it does not already have a 15 amp ATC fuse protecting the circuit, add KRV# 696343- Fuse – Holder – 15 Amp – 10 Ga – W/P – w/15 Amp Fuse – Optifuse – LPR-03BL – 10BL – 15A – DC – Blue. See Figures 4 and 5 for typical fifth wheel and travel trailer 12VDC distribution boxes.
  • Attached to a mini breaker with an inline fuse that is 20 amps or 15 amps. Change any 20 amp fuses to a 15 amp ATC fuse for the fuel controller circuit. See Figure 6.
  • Attached to a configuration of mini breakers, either to the mini breaker or power buss bar. Install KRV # 696343- Fuse – Holder – 15 Amp – 10 Ga – W/P – w/15 Amp Fuse – Optifuse – LPR03BL – 10BL – 15A – DC – Blue or similar part from stock. See Figure 6.

 

Note: In regards to the fuel controller wiring there are several red wires attached to the mini breakers. Test to make sure that you have the correct one by disconnecting the 10 gauge red wire and then testing the function of the fuel controller. The green lights will not light up on the controller if the power is properly disconnected.

 

Step 7

Test the function of the fuel controller. Pull the 15 amp fuse to verify that the controller is properly connected to the protected circuit. Proceed to warranty reimbursement.

 

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Chronology :

1/23/2023 – Report was made of a fire and reviewed a weekly TREAD audit.

1/23/2023 – Investigation of warranty claims into all failures of fuel system controllers opened.

1/31/2023 – ECI Fuel systems given claim data to open investigation into failures. Warranty claims for failures include 272 failures ranging from inoperative panels to miswired panels, claim dates started in April of 2021 to current. The fire claim that started the investigation happened on 1/19/2023. There were no field reports/service reports, and no death or injury claims.

2/2/2023 –.Keystone Safety Committee reviewed the information and concluded that the data reviewed indicated a unanimous vote for a voluntary recall. Investigation called for to determine affected unit range. All affected units were put on hold until a cause and remedy can be determined.

2/10/2023 – Investigation concluded of affected scope and range. Investigation of cause is ongoing.

 


12 Affected Products

Vehicles

MAKE MODEL YEAR
KEYSTONE CARBON 2021-2023
KEYSTONE FUZION 2021-2023
KEYSTONE IMPACT 2021-2023
KEYSTONE RAPTOR 2021-2023

 


9 Associated Documents

Recall Acknowledgement

RCAK-23V082-8339.pdf 645.787KB

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Defect Notice 573 Report

RCLRPT-23V082-7926.PDF 217.742KB

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Remedy Instructions and TSB

RCRIT-23V082-7097.pdf 1289.258KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V082-8996.pdf 264.869KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V082-0833.pdf 92.622KB

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Recall Quarterly Report #1, 2023-2

RCLQRT-23V082-7094.PDF 211.129KB

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ISSUED Renotification Notice

RCRN-23V082-7093.pdf 339.803KB

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Recall Quarterly Report #2, 2023-3

RCLQRT-23V082-0362.PDF 211.366KB

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Recall Quarterly Report #3, 2023-4

RCLQRT-23V082-4336.PDF 211.459KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V082&docType=RCL

 


 

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