21E063 – Fuel Hose Leak – Cummins L9 Diesel Engines

July 13, 2021 NHTSA CAMPAIGN NUMBER: 21E063000

Fuel Hose Leak

A fuel leak in the presence of an ignition source increases the risk of a fire.

 

NHTSA Campaign Number: 21E063

Manufacturer Cummins, Inc.

Components FUEL SYSTEM, DIESEL

Potential Number of Units Affected 2,922

 

Summary

Cummins, Inc. (Cummins) is recalling certain L9 Diesel Engines, with part number D563027BX03, that are equipped with a remote Stage 2 fuel filter and pressurized hoses. A fuel leak may occur from the fuel hose between the fuel pump and remote fuel filter head.

 

Remedy

Dealers will replace the fuel hoses, free of charge. Owner notification letters were mailed September 3, 2021. Owners may contact Cummins’ customer service at 1-800-286-6467. Cummins number for this recall is C2465.

 

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.

 

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Technical Service Bulletin

Technical Service Bulletin: TSB210184	Released Date: 25-Aug-2021
Remote Mount Fuel Line Replacement Procedure: External Fuel Leaks, Fault Codes 559 and 4691

 

Remote Mount Fuel Line Replacement Procedure:

External Fuel Leaks, Fault Codes 559 and 4691

 

Warranty Statement

The information in this document has no effect on present warranty coverage or repair practices, nor does it authorize TRP or Campaign actions.

 

Contents

Product Affected

• L9 CM2350 L133C

• L9 CM2450 L126B

 

Issue Summary

Symptoms:

• External fuel leak

• Loss of fuel pressure

• FC559

• FC4691

• Crank no start

• Engine shutdown

 

Root Cause:

The fuel line clamps do not provide adequate sealing pressure on the quick disconnect line barb for the joint to remain sealed properly in service. Additionally, the fuel line is prone to kinking when forced into a tight bend radius and flexing when pressurized during start up.

 

Verification

Note : The new fuel lines are approximately 3.5 mm [ 0.137 in ] smaller in diameter and may require a different support solution or a modification to the existing supports to provide the appropriate clamping pressure. Verify the fuel line is held firm and not able to move within the clamp to minimize risk to other failure modes.

 

This issue is only for remote mount stage 2 fuel filter to fuel pump supply and return fuel lines. The remote mount stage 2 fuel filter is mounted off-engine. The mounting location for the fuel filter head assembly varies depending on vehicle type. Examples of possible mounting locations included in Figure 1 below.

 

Figure 1, Example Locations of the Remote Mount Stage 2 Fuel Filter.

 

Prior to installation of all fuel lines, verify both ends of the fuel lines are capped or protected from the ingress of debris. Verify the fuel lines do not contact the floor during any portion of the assembly process.

 

Identify stage 2 fuel supply and return fuel lines.

 

• One fuel line runs from the stage 2 fuel filter head quick connect fitting to the fuel pump inlet quick connect fitting.

• The second fuel line will run from the fuel pump outlet quick connect fitting to the stage 2 fuel filter head return quick connect fitting.

• Figure 2 below indicates the fuel filter head outlet and fuel pump inlet connection points.

• Figure 3 below indicates the fuel pump outlet and fuel filter head return connection points.

• Verify the fuel lines are routed correctly between the outlet of the filter head to the inlet of the pump and outlet of pump to the fuel filter head return or premature fuel pump wear can occur.

 

Figure 2, Indication of Fuel Pump Inlet and Fuel Filter Outlet Quick Connect Fitting Locations.

 

Figure 3, Indication of Fuel Pump Outlet and Fuel Filter Return Quick Connect Fitting Locations.

 

Resolution

• See corresponding Service Manual. Reference 006-024 in Section 6 for guidance on the initial checks, preparatory steps, and instructions on removing the fuel line quick disconnects.

• As part of the fuel line removal process, support clips, clamps, or ties may need to be removed. The style of fuel line support could vary by vehicle model. Additionally, the removal of adjacent components may be required to route the fuel line appropriately. See equipment manufacturer service information for the component(s) at issue prior to such removal.

• Replace the low-pressure fuel supply and return lines with the appropriate new fuel lines. Table 1 indicates the relationship between the existing fuel line part number and the new fuel line part number.

• Install new fuel lines in the same routing and orientation as the existing lines and verify all support and tie locations are installed appropriately.

• Fuel lines should be routed such that fuel could not leak onto hot piping under any operating conditions.

• Fuel lines must be run at least 5 cm [ 2 in ] from hot components.

• Fuel supply lines are to be routed as directly as possible from the tank to the engine, avoiding both upward and downward loops. Upward loops can act as air traps, which can cause erratic engine operation, and downward loops can act as water traps, which can freeze and block fuel flow.

• The fuel lines must be routed to avoid kinking.

• After completing the fuel line replacement, see corresponding Service Manual. Reference procedure 006-024 in Section 6 for finishing steps.

 

Table 1, Service Parts

Existing Part Number	Obsolete and Superseded	New Part Number	Line Length Meters [ ft ]
5563641	Yes	5717302	1.22 meters [ 4 ]
5563642	Yes	5717303	1.83 meters [ 6 ]
5563643	Yes	5717304	0.61 meters [ 2 ]

 

Document History

Date	Details
2021-8-20	Module Created

 

Last Modified: 25-Aug-2021

 

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A CUMMINS FIELD CAMPAIGN

Please Deliver To: Service Managers and Warranty Decision Makers

FROM: Cummins Global Warranty Administration Communications

Subject: L9 CM2350 L133C and L9 CM2450 L126B Remote Mount Stage 2 Fuel Hose Safety Campaign

Number: C2465

Date: 24-Aug-2021

Expires: 26-Aug-2055 (U.S./Canada)

26-Aug-2055 (International)

Attention: U.S. / Canadian Dealers

U.S. / Canadian Distr./Branches and Div. Offices

Worldwide distr./ branches and Div./Reg Offices (Automotive)

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

 

DESCRIPTION:

This Safety Campaign is being issued to address inadequate design and quality of the remote mount stage 2 fuel hose assembly. These engines are equipped with a remote Stage 2 fuel filter (Option Numbers FF90942, FF90943, FF90944, FF91044) which includes pressurized fuel hoses. The recall consists of the entire population of MY21 engines built with a remote fuel filter option prior to the introduction of a new fuel hose design.

NOTE: This field action provides retroactive coverage for repairs made in anticipation of and prior to the release of this publication.

 

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:

• Remove the obsolete remote mount fuel hoses and replace them with new and improved hoses. Refer to TSB# 210184 and Service Procedure 006-024 Fuel Supply Lines in the appropriate service manual.

 

MATERIAL DISPOSITION:

Materials removed as a result of this field action must be scrapped.

 

REIMBURSEMENTS:

Parts:

NOTE: All parts listed are OPTIONAL. Claim only the parts required to complete the repair.

The following parts are covered under this field action:

Part Number	Quantity	Description
571730200	2	HSE,FUL (OPTIONAL)
571730300	2	HSE,FUL (OPTIONAL)
571730400	2	HSE,FUL (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: SRTs listed are OPTIONAL. Select ONLY the appropriate SRTs for the repair performed.

 

Labor using applicable Access Code and Time:

SRT Code	Description	Time
00-90X	Administrative time
06-0WP	Fuel Supply Lines – Remove and Install – L9 CM2350 L133C
06-0X6	Fuel Supply Lines – Remove and Install, All – L9 CM2450 L126B

 

Travel:

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

NOTE: Please schedule the Technicians time to maximize the number of units that can be repaired on a single visit. When filing claims for multiple ESNs, where travel or towing is required, travel or towing can be filed to ONLY one (1)

ESN.

 

Other Claimables:

Consumables are covered under this field action.

NOTE: 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 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:	North America Distributor = X
Pay Code:	North America Dealer = D
Pay Code:	International Distributor = I
Pay Code:	International Dealer = R
Failure Code:	WFLTOA

 

Attachments c2465_esn-list.xlsx

 

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*** IMPORTANT SAFETY RECALL ***
NHTSA Recall No. 21E-063

 

July 16, 2021

 

OEM Customer
XXXX Street Address
City, ST 12345-6789

 

Dear Cummins OEM Customer:

 

We are writing to inform you that Cummins Inc. has determined that a safety-related defect exists in certain EPA MY 2021 L9 engines that were manufactured between March 27, 2019 and June 15, 2021.  Cummins has initiated a recall of the subject engines.  Our records indicate that some of these engines have been 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 July 13, 2021.  As more fully described in the Defect Notification, a fuel leak may occur in the fuel hoses between the fuel pump and remote filter head,which may increase the risk of a fire.

 

Enclosed is a list of Engine Serial Numbers for affected engines that our records indicate were shipped to your plants.  For engines 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.

 

Cummins will conduct a safety campaign to remedy the issue with fuel hoses of a different design.  Availability of parts and Cummins’ plan for support to remedy engines/vehicles still in your inventory will be communicated separately.  Please contact your Cummins OEM Customer Quality representative for more information.  Please note that Federal law prohibits delivery of these engines, or vehicles equipped with these engines, 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,

 

Account Manager

 

Enclosures:

 

1. Cummins Part 573 Defect Notification
2. List of Engine Serial Numbers.

 

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*** IMPORTANT SAFETY RECALL***
NHTSA Recall No. 21E063
Cummins Campaign #C2465

 

September 3, 2021

 

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 MY 2021 Cummins L9 engines manufactured between March 27, 2019 and June 15, 2021.

 

This notice applies to the engines in your vehicles listed on the enclosed table.

 

WHAT IS THE PROBLEM?

A fuel leak may occur in the fuel hoses between the fuel pump and remote filter head.  A fuel leak in the presence of an ignition source may increase the risk of a fire. Persons operating in or around the vehicle may see smoke before sufficient heat creates a fire.

 

WHAT WILL CUMMINS DO?

Cummins has released field Safety Campaign #C2465 to correct this condition by replacing the subject fuel lines with fuel lines of a new design. This campaign is currently available at Cummins Distributors and authorized Warranty Dealers. The repair will be completed free of charge and most applications will require approximately 2 hours to complete.

 

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.

 

We urge you to have this repair performed as soon as possible. In the meantime, however, Cummins advises you to periodically check the remote fuel filter hoses for signs of leaking and immediately seek repairs if leaks are identified.

 

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 1-800-CUMMINS (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 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 one or more of the vehicles listed on the enclosed table, please forward this notice to the new owner(s) 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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1 Affected Product

Equipment

BRAND	PART NO.	PRODUCTION DATES
CUMMINS	L9

 

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11 Associated Documents

Manufacturer Notices(to Dealers,etc)

RCMN-21E063-7774.pdf 132.578KB

 

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Defect Notice 573 Report

RCLRPT-21E063-8676.PDF 239.11KB

 

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Recall Acknowledgement

RCAK-21E063-2853.pdf 689.945KB

 

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Recall Quarterly Report #1, 2021-3

RCLQRT-21E063-8139.PDF 211.108KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21E063-9659.pdf 171.936KB

 

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Recall Quarterly Report #2, 2021-4

RCLQRT-21E063-9731.PDF 211.219KB

 

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Recall 573 Report – Amendment 2

RCLRPT-21E063-2524.PDF 239.168KB

 

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Recall 573 Report – Amendment 1

RCLRPT-21E063-1724.PDF 239.051KB

 

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Remedy Instructions and TSB

RCRIT-21E063-4093.pdf 1079.102KB

 

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Miscellaneous Document – 2021-3 Quarterly Report Supplemental

RMISC-21E063-9983.pdf 201.862KB

 

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Remedy Instructions and TSB

RCRIT-21E063-3176.pdf 63.881KB

 

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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=21E063&docType=RCL

 

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