S | Technical Service Bulletin

Technical Service Bulletin: TSB230017 Released Date: 30-Jun-2023

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

A220032655 C220059839 F220098436 G220117503
A220031047 C220058420 F220098740 G220117088
A220032186 C220059954 G220114702 H220129254
A220032178 C220058621 G220114722 H220129823
A220034303 C220058413 G220114742 H220135874
B220039074 C220058636 G220114743 H220135237
A220033251 C220063413 G220114763 H220136001
B220039075 C220063287 G220114782 H220135905
C220052086 C220058421 G220114802 1220145353
B220039265 C220059050 G220116098 1220145342
C220052008 H220124534 G220117202 J220156672
C€220052083 F220097262 G220117086 J220156436
A220030813 F220097542 G220117222

C220058786 F220097462 G220117242

C220058292 F220097527 G220117087

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)

17101731

Figure 1, Hole Location From Roadside Exterior

17101732

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

e 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

17101733

Figure 3, Fuel Drain Access Panel Removed

Step 2: Disconnect both harnesses on the roadside of the unit

« Remove the bolts securing each harness

% :

Remove bolts

17101734

Figure 4, Harness Bolt Location

¢ Pull back the harness covers
e Press down on the orange button and lift the gray lever to the left to release the connectors

ro

=
Hi i

17101735

Figure 5, Connector Disconnect

¢ Disconnect the harnesses

Figure 6, Both Harnesses Disconnected

17101736

Step 3: Grind/clean areas for welding

¢ Grind a small spot along the top of the roadside channel for welder ground

Channel

=a

al? _—z 17101737

Figure 7, Ground Location to Grind/Clean

¢ Grind the top two seams that touch the corner of the manufacturing process hole

Figure 8, Area of Seam to Grind/Clean

17101738

Step 4: Weld along the top two seams that touch the corner of the manufacturing process hole

17101739

Figure 9, Finished Weld

Step 5: Spray paint welded and ground areas

Step 6: Reinstall the fuel drain access panel bolts

17101740

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