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February 4, 2020 NHTSA CAMPAIGN NUMBER: 20E003000
Possible Loss of Drive System and Power Steering
A sudden loss of drive power and loss of power steering increases the risk of a crash.
NHTSA Campaign Number: 20E003
Manufacturer Cummins Inc.
Components POWER TRAIN
Potential Number of Units Affected 76
Summary
Cummins Inc. (Cummins) is recalling certain PowerDrive EV drivetrains, part numbers 4000EV, 6000EV, and 7000EV sold for installation in school buses, step vans and medium-duty trucks. A connector within the wire harnesses may become unplugged and cause loss of communication between control modules, resulting in sudden loss of drive power and power steering.
Remedy
Cummins will notify the vehicle manufacturers that purchased the units, and Cummins will install a cable tie on the connector to maintain the connector locking tab in the locked position, free of charge. The recall began March 12, 2020. Owners may contact Cummins 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.
R20AL
IMPORTANT SAFETY RECALL NOTICE
NHTSA Recall Number: 20V-074 School Bus
DATE: March 12, 2020
Dear Blue Bird Owner:
SUBJECT: RECALL R20AL, Cummins Power Drive EV Wiring Harness Connection Failure
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
This important safety recall notice applies to your bus(es) identified by both Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet. If you no longer own the subject bus(es), please complete the appropriate section of the yellow cover sheet and return to Blue Bird in the enclosed pink postage prepaid envelope.
Blue Bird Body Company is recalling certain model year 2018-2019 Vision School Buses manufactured from January 19, 2019 through September 9, 2019, and certain model year 2018-2019 All American School Buses manufactured from August 1, 2018 through January 30, 2020. On the subject buses, Blue Bird and Cummins have determined that certain Vision and All American electric school buses sold with PowerDrive 7000 EV electric drivetrain units, a connector within the wire harnesses installed in the subject EV drivetrains may be susceptible to becoming unplugged. If the connector becomes unplugged, under certain circumstances the communication between control modules may be lost and the system may command off the high voltage contactors, resulting in unexpected loss of all systems powered by high voltage, including the traction drive system and power steering. A sudden and simultaneous loss of motive power and loss of power steering may increase the risk of a crash.
To correct this condition, Cummins will arrange to have the remedy performed that addresses this condition. The remedy is to install a cable tie around the connector body, routed under the connector locking tab, forcing it into the locked position so that it cannot unplug. Cummins will work directly with affected customers and a limited number of service engineers and field technicians to implement the remedy. Cummins expects to be able to immediately begin working with vehicle owners to have the remedy installed on their school buses. The remedy will be performed free of charge and will take four hours to complete.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Reimbursements will be made in accordance with the requirements of the National Highway Transportation Safety Act, Title 49 Code of Federal Regulations, Parts 573 and 577.
If Blue Bird Body Company should fail to or is unable to remedy this condition without charge to you, you may contact:
ADMINISTRATOR
NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
1200 NEW JERSEY AVENUE, SE
WASHINGTON, D.C. 20590
Or, you may call The National Highway Traffic Safety Administration toll free at: 1-888-327-4236 TTY 1-800-424-9153 or go to: http:/www.safercar.gov
BLUE BIRD BODY COMPANY
3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021
SEOCONTENT-START
February 13, 2020
Internal Use Only
CAN Y Cable Ties: Inspection and Repair
2
CAN Y Inspection & Repair
Internal Use Only
LOTORequired: LOTO 12V
Overview
Cable ties are used on all 3-pin Deutsch CAN connectors to secure connector locks and prevent accidental disconnection
Some harnesses are missing these cable ties
Equipment Needed
Flashlight
Cross-point screwdriver
Narrow 4” cable ties (MS3367-4-9)
Cabin, BDU MCU and Frame Harness Wiring Diagrams
3
CAN Y Inspection & Repair
Internal Use Only
On PowerDrive systems, 3 harness assemblies contain these connectors:
BDU and MCU LV Harness
Frame Assembly Harness
Cabin Assembly Harness
Blue Bird EV Bus
Freightliner eM2
4
CAN Y Inspection & Repair
Internal Use Only
Vehicle specific wiring diagram can be found here:
https://technical.cummins.com/sites/CC31138/Service%20Information/PowerDrive%20Service%20Information/3%20-%20Wiring%20Harnesses
Or on QuickServe Onlineusing
Engine Model Search > Automotive > BES > CM0904 EV104B (Blue Bird only)
Printed copies are recommended for this repair
5
Y1.1
Cabin Harness (Blue Bird)
Internal Use Only
Cabin Harness P/N 300118 (Same for type C & D)
7 Y’s, 21 Cable Ties
Physical location:
Cabin of bus
Behind dashboard
Cabin Assembly Harness
6
Cabin Harness (Blue Bird)
Internal Use Only
Procedure
1.
Remove Dashboard Instrument Cluster
2.
Remove center Switch Panel (above radio)
3.
Inspect the Y’s listed for missing cable ties on the locks and replace where missing.
4.
Using the printed schematic check of each connector to ensure that ALL Y’s were inspected
5.
Replace removed panels
CABLE TIES MISSING
CABLE TIES REPLACED
7
Frame Harness (Blue Bird)
Internal Use Only
Type C Frame Harness P/N 300131
Type D Frame Harness P/N 300034 (shown)
16 Ys, 48 Cable Ties
Physical location:
from Cabin bulkhead
to rear of bus
Routes underneath the vehicle between the frame rails
Frame Assembly Harness
8
Frame Harness (Blue Bird type D)
Internal Use Only
FRONT OF BUS
9
Frame Harness (Blue Bird type C)
Internal Use Only
FRONT OF BUS
10
Frame Harness (Blue Bird)
Internal Use Only
Procedure
1.
Lift vehicle (optional)
2.
Work from X200 (bulkhead connector) backward
3.
Inspect the Y’s listed above for missing cable ties on the locks and replace where missing.
4.
Using the printed schematic check of each connector to ensure that ALL Y’s were inspected
5.
Place any removed components or harness supports removed for access
CABLE TIES MISSING
CABLE TIES REPLACED
11
BDU MCU Harness (Blue Bird)
Internal Use Only
BDU MCU Harness P/N 300076 (same for type C & D)
6 Y’s, 16 Cable Ties
Cable tie not needed on “Service Port”
Physical location:
Above HV battery strings
Between frame rails
2 Y’s above BDU 1
4 Y’s above BDU 2
BDU and MCU LV Harness
BDU 1
BDU 2
12
FRONT OF BUS
No Tie Here
No Tie Here
BDU MCU Harness (Blue Bird)
Internal Use Only
Procedure
1.
Lift vehicle (optional)
2.
Inspect the Y’s listed above for missing cable ties on the locks and replace where missing.
3.
Using the printed schematic check of each connector to ensure that ALL Y’s were inspected
4.
Cable Tie is not needed on BDU SERVICE PORT
5.
Place any removed components or harness supports removed for access
13
Other PowerDrive Vehicles
Internal Use Only
Procedure
Find applicable wiring diagrams here:
https://technical.cummins.com/sites/CC31138/Service%20Information/PowerDrive%20Service%20Information/3%20-%20Wiring%20Harnesses
1.
Inspect the Y’s for missing cable ties on the locks and replace where missing.
2.
Work through all 3 harnesses:
1.
Frame Assembly Harness
2.
Cabin Assembly Harness
3.
BDU MCU Harness
3.
Cable Ties are not needed on BDU SERVICE PORTS
4.
Place any removed components, panels or harness supports removed for access
CABLE TIES MISSING
CABLE TIES REPLACED
1144
*** IMPORTANT SAFETY RECALL *** NHTSA Recall No. 20E-003
February 5, 2020
We are writing to inform you that Cummins Inc. has determined that a safety-related defect exists in certain Power Drive 4000EV/6000EV/7000EV drivetrain systems that were manufactured between June 7, 2018 and October 24, 2019. Cummins has initiated a recall of the subject systems. Our records indicate that some these systems were shipped to you.
A copy of Cummins’ initial Part 573 Defect Notification report is enclosed. This notification was submitted to the National Highway Traffic Safety Administration (NHTSA) on February 4, 2020. As more fully described in the Defect Notification, the system may unexpectedly command off the high voltage contactors, resulting in unexpected loss of all systems powered by high voltage, including the traction drive system and power steering. A sudden and simultaneous loss of motive power and loss of power steering may increase the risk of a crash.
Enclosed is a list of systems 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. Cummins will conduct the recall, including notifying owners pursuant to 49 CFR Part 577, performing the remedy, and submitting quarterly status reports to NHTSA. Cummins is requesting that you provide the associated vehicle model identification, VINs and owner contact information to facilitate owner notification. Please work with your Cummins account team leader to ensure that the requested information is provided to Cummins as soon as possible.
For systems/vehicles that are still in your inventory, please contact – to arrange for repairs. 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.
Cummins 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,
Cummins Inc.
Enclosures:
1 Affected Product
Equipment
BRAND | PART NO. | PRODUCTION DATES |
CUMMINS | POWERDRIVE EV |
14 Associated Documents
Miscellaneous Document – 20E-003 1Q2020 Qtrly Report Supplement
RMISC-20E003-1985.pdf 163.353KB
Recall Quarterly Report #1, 2020-1
RCLQRT-20E003-9089.PDF 211.125KB
Recall 573 Report – AMENDMENT 1
RCLRPT-20E003-9510.PDF 215.698KB
ISSUED Owner Notification Letter(Part 577)
RCONL-20E003-1792.pdf 538.156KB
Miscellaneous Document – 20E-003 2Q2020 Qtrly Report Supplement
RMISC-20E003-8424.pdf 164.219KB
Recall Quarterly Report #2, 2020-2
RCLQRT-20E003-9726.pdf 210.932KB
Recall Acknowledgement
RCAK-20E003-2472.pdf 244.254KB
Manufacturer Notices(to Dealers,etc)
RCMN-20E003-7457.pdf 124.934KB
Defect Notice 573 Report
RCLRPT-20E003-7076.PDF 215.567KB
Remedy Instructions and TSB
RCRIT-20E003-7585.pdf 2902.881KB
Miscellaneous Document-20E-003 3Q2020 Qtrly Report Supplement
RMISC-20E003-8601.pdf 163.656KB
Recall Quarterly Report #3, 2020-3
RCLQRT-20E003-3309.PDF 211.307KB
Miscellaneous Document – 20E-003 4Q2020 Qtrly Report Supplement
RMISC-20E003-5961.pdf 165.265KB
Recall Quarterly Report #4, 2020-4
RCLQRT-20E003-0092.PDF 211.415KB
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=20E003&docType=RCL
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- 🚒【Available for Caterpillar】exclusively designed for Caterpillar engines (C7, C9, C11, C13, C15, C32, and more), you can perform top-notch diagnostics to keep your trucks running reliably. Compatible with popular truck models like Kenworth, Peterbilt, Freightliner, International, Mack, and Volvo.
- 🚛【Available for Paccar&Detroit】ANCEL HD3400 PRO is compatible with a wide range of engine types, including Detroit engines (Series 50, Series 55, Series 60, OM501, OM502, DD5, DD13, DD15, DD16,MBE 900, MBE 4000, DD8, DDDL 6, DDDL 7, CPC2, CPC02T, CPC04T, CPC302T and More) and Paccar engines(PX-7, PX-9, MX-11, MX-13 and more). like medium-duty or light-duty trucks, or even semi-trucks
- 🚒【Superb Lifetime Free Update,Best Bang For The Buck】ANCEL HD3400 PRO diesel code reader allow our customers get the latest version with free update via WIFI,With Lifetime Free Update,HD3400 PRO is way more valuable by comparing with the other OBD diagnosis,which can save hundreds of dollar for our customers!
Last update on 2024-04-11 / Affiliate links / Images from Amazon Product Advertising API
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