Technical Service Bulletin
Technical Service Bulletin: TSB220216
C500D6RE Exhaust Bellow Cracking Issue

Released Date: 22-Apr-2025

C500D6RE Exhaust Bellow Cracking Issue
Warranty Statement
The information in this document authorizes specific changes to the repair practice for failures covered under product warranty coverages.

Contents
Product Affected
C500D6RE
Issue
Symptom:
Melted downpipe blanket
Melted insulation panels from hot exhaust
Exhaust gas leaking inside enclosure
Root Cause:
Assembly issue putting pressure on the exhaust bellow causing it to crack

Verification/Confirmation
Inspect both ends of the exhaust insulation for soot. If soot is found remove the insulation and inspect the bellow.
Inspect the ceiling area and exhaust insulation above the radiator. If any melting is observed, proceed to the resolution to replace the exhaust bellow.
Resolution
On generator sets that experience exhaust bellow failure, the damaged exhaust pipe assembly will be removed and replaced with new parts. Careful attention must be
paid when assembling the new exhaust assembly to ensure that the bellow is installed in a neutral state.
Refer to the service instructions for repair steps and the service parts availability for part numbers and steps to get parts.

Service Instruction
Step 1: Remove Roof
A. Two roof panels of the enclosure need to be removed to allow access to the exhaust assembly
B. Cut caulk between roof panels

Figure 1, Roof Removal
C. Remove exhaust support bracket from roof - Note : Only the bottom nut needs to be removed from the all-thread rod (the rod can remain attached to the roof)

Figure 2, Exhaust Clamp Removal
D. Remove all necessary bolts – Note: Enclosure hardware will be reused

Figure 3, Exterior Roof Mounting Bolts

Figure 4, Interior Roof Mounting Bolts

Figure 5, Hidden Interior Roof Mounting Bolts

Figure 6, Qty 5 Hidden Roof Seam Bolts
E. Lift roof off unit – Note: Panels can be separated or lifted together as shown
Warning: Use caution when lifting. Follow all local lifting regulations.

Figure 7, Removing Roof
Step 2: Remove damaged pipe assembly
A. Drill out rivets holding heat shield to divider wall and remove heat shield

Figure 8, Heat Shield Mounting Rivet
B. Remove insulation wrap from pipes
C. Remove SS band clamp at turbo elbow

Figure 9, Remove Insulation Wrap on Exhaust
D. Remove SS band clamp between pipe assemblies

Figure 10, Exhaust Joint
E. Unbolt exhaust assembly from SCR (Selective Catalytic Reduction)

Figure 11, Unbolt Exhaust from SCR
Step 3: Install new pipe assembly (Note: Assembly order needs to be followed to ensure bellows is in neutral position)
A. Slide EXT29-0002-W11 though divider wall

Figure 12, New Exhaust Section
B. Bolt EXT29-0002-W11 to SCR with GSK-ANS08-T-STK exhaust gasket
C. Slide EXT29-0002-W10 into EXT29-0002-W11 (Do NOT install Riker Band Clamp at this point)

Figure 13, New Exhaust Adjustment
D. Slide EXT29-0002-W10 over turbo elbow (Do NOT install Riker Band Clamp at this point)

Note: ensure bellow is in a neutral position – If centerline of bellows is not in-line with adjacent tubing, adjust assemblies at the overlap joints until all offsets are
removed

Figure 14, Neutral Bellow Reference
E. Install RIKER-TEC600 at each joint, make sure clamps are installed evenly between the two pipe joints.
Ei. Evenly tighten bolts and torque to 50lbs
F. Double check bellows is still in neutral position
Step 4: Reassemble
A. Install insulation wrap
B. Install top portion of exhaust clamp under heat shield
C. Rivet heat shield to divider wall
D. Install roof panels
Warning: Use caution when lifting. Follow all local lifting regulations.
E. Caulk roof seam
F. Install exhaust support clamp

End of repair
Warranty Claim filing instructions:
To procure replacement parts, a Purchase Order (PO) to purchase parts from Girtz will be required. Include PO amount in warranty claim if failure occurred on unit under
Cummins factory warranty.
Fail Code: OXEUBR
Account Code: 67
Applicable SRTs:
00-901: 0.3 hours- Administrative time (shop)
11-2MM: 6.8 hours- Exhaust Bellow R&I C500D6RE

To order replacement parts, contact Girtz via email at [email protected]
Note: repairs and parts outside of warranty will not be covered by Cummins Inc. and responsibility of the customer.
Service Parts Availability
Service parts are to be ordered from Girtz via email at [email protected]
See Table 1 for part numbers.
Table 1, Service Parts
Find Number (see Figure 15)

Part Description

Part Number (Girtz)

N/A

6” Exhaust Assembly (engine side)

EXT29-0002-W10

N/A

6” Exhaust Assembly (SCR side)

EXT29-0002-W11

N/A

6” Stainless Steel Band Clamp

RIKER-TEC600

N/A

8” Exhaust Gasket

GSK-ANS08-T-STK

Table 1, Service Parts
Find Number (see Figure 15)

Part Description

Part Number (Girtz)

N/A

Exhaust Wrap (if damaged)

EXT29-0002-R01

N/A

Rivet

RIV.AL.T.187-3_8

N/A

Caulk

DOWSIL 700 INDUSTRIAL GRADE SILICONE
SEALANT

29

Insulation Panel - 2.5LBS/CU. FT. (if damaged)

INS12-0004-012

30

Insulation Panel - 2.5LBS/CU. FT. (if damaged)

INS12-0004-013

31

Insulation Panel - 2.5LBS/CU. FT. (if damaged)

INS12-0004-014

32

Insulation Panel - 2.5LBS/CU. FT. (if damaged)

INS12-0004-015

33

Insulation Panel - 2.5LBS/CU. FT. (if damaged)

INS12-0004-016

34

Insulation Panel - 2.5LBS/CU. FT. (if damaged)

INS12-0004-017

35

Insulation Panel - 2.5LBS/CU. FT. (if damaged)

INS12-0004-018

Figure 15, Insulation Parts Diagram

Document History
Date

Details

2022-10-21

Module Created

2023-2-27

Non-Product Problem Solving (PPS)

2023-3-20

Non-Product Problem Solving (PPS)

2023-8-25

Non-Product Problem Solving (PPS)

2024-9-27

Non-Product Problem Solving (PPS)

Last Modified: 22-Apr-2025