NHTSA ID Number: 10235522
Manufacturer Communication Number: TSB230017
TSB/Document Date: 2023-05-04
Summary
This Technical Service Bulletin describes the verification and resolution of the issue of the dike tank leaking captured fluid. This is an update to the previously submitted communication.
C500D6RE Dike Tank Corner Weld Issue
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Technical Service Bulletin
Technical Service Bulletin:
Released Date: 24-Apr-2023
TSB230017
C500D6RE Dike Tank Corner Weld Issue
C500D6RE Dike Tank Corner Weld Issue
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
• C500D6RE
Issue
Symptom:
• Dike tank may leak captured fluid
Root Cause:
• Incomplete corner weld during manufacturing of the dike tank.
Verification/Confirmation
If the unit serial number is listed in Table 1, an inspection must be performed to verify
the manufacturing process hole was not filled prior to leaving the factory.
Table 1, Potentially Affected Generator Set Serial Numbers
A220026525
C220055006
F220094291
G220113155
A220026926
C220055007
F220094293
G220113147
A220026953
C220055011
G220110413
H220126129
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Table 1, Potentially Affected Generator Set Serial Numbers
A220026954
C220055008
G220110415
H220126130
A220029829
C220055009
G220110414
H220131118
A220033339
C220055010
G220111248
H220131422
A220029828
C220058296
G220111249
H220131424
A220033340
C220058295
G220110407
H220131425
B220038629
C220055003
G220110412
I220138333
B220038630
C220055004
G220110411
I220138334
B220038628
F220091832
G220113144
I220138335
B220038638
F220094285
G220113145
I220141855
A220026524
F220094290
G220113146
C220055012
F220094286
G220113142
C220055005
F220094294
G220113143
Inspection Procedure:
1. Make sure the unit is level so the water is evenly distributed across the bottom of the
dike tank.
2. Fill the dike tank with water until the water level is approximately 6 inches deep
(approximately 50 gallons).
Note: Take special care not to spill water around unit to reduce likelihood of
misdiagnosing a leaking dike tank.
3. Do NOT fill the nose area where the DEF tank is located. This area has drains and will
not hold water
4. Visually inspect underneath the unit checking for leaks. Particular attention should be
paid to the location of the manufacturing process hole. The manufacturing process hole
can be viewed from underneath the unit towards the rear roadside (left/driver side). It is
located on the top corner where the three planes meet. (Weld wire shown below in
Figure 2 to indicate location)
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Figure 1, Hole Location From Roadside Exterior
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Figure 2, Manufacturing Hole Viewed From Underneath Tank
5. If a leak is found at the manufacturing process hole, proceed to the Resolution
section.
6. If a leak is found elsewhere, contact 1800-Cummins
with a picture showing the
location of the leak for further instructions
Note: Some dike tanks may already have standing water in them. If that is the case,
further inspection is not required.
7. After the unit has been inspected, drain the water from the dike tank via the
containment tank drain located at the rear exterior of the unit. If no leak is found, no
further action is required.
Resolution
Clean surfaces and repair hole by welding it closed. Proceed to the service
instructions section below for welding procedure.
Service Instructions
Step 1: Verify there are no fluids inside the dike
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• Remove the 12 bolts on the fuel drain access panel located on the rear of the unit
• Visually inspect the inside of the dike to verify there are no residual fluids present
• If fluids are present, drain the dike until fluids are no longer present
Figure 3, Fuel Drain Access Panel Removed
Step 2: Disconnect both harnesses on the roadside of the unit
• Remove the bolts securing each harness
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Figure 4, Harness Bolt Location
• Pull back the harness covers
• Press down on the orange button and lift the gray lever to the left to release the
connectors
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Figure 5, Connector Disconnect
• Disconnect the harnesses
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Figure 6, Both Harnesses Disconnected
Step 3: Grind/clean areas for welding
• Grind a small spot along the top of the roadside channel for welder ground
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Figure 7, Ground Location to Grind/Clean
• Grind the top two seams that touch the corner of the manufacturing process hole
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Figure 8, Area of Seam to Grind/Clean
Step 4: Weld along the top two seams that touch the corner of the manufacturing
process hole
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Figure 9, Finished Weld
Step 5: Spray paint welded and ground areas
Step 6: Reinstall the fuel drain access panel bolts
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Figure 10, Reinstall Fuel Drain Cover
Step 7: Reconnect both roadside harnesses
•
•
•
•
Plug both harnesses back in
Move the levers to the right
Put the covers back on
Fasten the bolts with appropriate hand tool
End of Repair
Warranty Claim Filing Instructions:
Fail Code: OFTFXO - For inspection, no leak found. Please include reference number
GWC0444 when submitting claims
Fail Code: OFTFLF - For units with a leak. Please include reference number GWC0444
when submitting claims
Account Code: 67
Applicable SRTs:
00-901: 0.4 hours- Administrative time (shop)
99-999: 1 hours- Dike Tank Inspection
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99-999: 2 hours- Dike Tank Repair
Can include welding consumables in claim (Maximum of $20 USD).
Document History
Date
Details
2023-1-31
Module Created
2023-4-18
Non-Product Problem Solving (PPS)
Last Modified: 24-Apr-2023
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TSB/Document ID: TSB230017
Replacement Service Bulletin Number:
MFR Communication Date: 2023-04-24
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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