Technical Service Bulletin
Technical Service Bulletin: TSB250073
C500D6RE and C1000D6RE Cooling Pack Replacement Instructions

Released Date: 29-Aug-2025

C500D6RE and C1000D6RE Cooling Pack Replacement Instructions
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
C1000D6RE

Issue Summary
Symptom:
Coolant leak from crack in radiator core
Root Cause:
Over constrained radiator core

Verification
If a coolant leak is observed from the radiator core, proceed to the resolution section.

Resolution
A revised service cooling package assembly (Radiator), Part Number, A077Y449 and Mounting Conversion Kit, Part Number, A078L782 have been released.
Note: For customers with cooling package assembly, Part Number A063P162, contact Josh Dennis (GK724@cummins.com) for assistance with additional fan guard
and radiator pipes required for upfit to new cooling package, Part Number A077Y449.
Note: A revised exhaust bellow kit has also been released. If the unit experiencing the radiator failure, the exhaust bellow should be inspected for failure during the
radiator repair. If a bellow failure is observed, file a separate warranty claim.

Service Instructions
To replace the cooling package assembly with the revised cooling package assembly, follow the steps below.
Removal of original cooling package, for C500D6RE model generator sets
Special Tools Needed:
Crane or chain hoist
WARNING
Heavy Load
Incorrect lifting or repositioning can cause severy personal injury or death.
Use a hoist of sufficient capacity for liftin and moving the radiator assembly.
WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Make sure the radiator cap is properly secured before operating the generator set.
1. LOTO unit
2. Drain engine coolant
3. Remove bolts to open side enclosure doors at the front side of the enclosure
4. Remove front nose cone

Figure 1, Nose Cone Removal
5. Cut the middle silicone seal in roof joint

Figure 2, Silicone Seal in Roof
6. Remove the top exhaust mounting clamp
Note: Inspect exhaust bellow, discard and install the revised bellow if the bellow is failed.

Figure 3, Exhaust mounting Clamp
7. Remove heatshield from bulkhead

Figure 4, Heat Shield Mounting Location
8. Remove front two roof panels, panels can be left together for removal.
9. Remove crossmember brackets (find #1 and #2 in Figure 5)

Figure 5, Crossmember Bracket Removal
10. Remove exhaust pipe wrap insulation
11. Remove exhaust clamp

Figure 6, Exhaust Pipe
Note: Inspect exhaust bellow, discard and install the revised bellow if the bellow is failed.

12. Remove exhaust flange pipe connection to SCR and slide exhaust pipe out the front.

Figure 7, Flange Pipe Removal from SCR
13. Remove DEF fill hose from filler neck, leave hoses carefully down in chassis
14. Unmount DEF heater pump from SCR subbase, leave pump down in chassis with hoses connected

Figure 8, DEF Hoses and Heater
15. Disconnect electrical connections to SCR
16. Remove SCR and mounting assembly together, leave SCR mounted to the large mounting shelf, and leave shelf mounted to SCR subbase.

Figure 9, SCR and Shelf Assembly Removal

17. Remove front radiator shroud

Figure 10, Radiator Shroud Removal
18. Remove aluminum deflector at base of radiator shroud, find #1 in Figure 11
19. Remove lower front radiator bracket, find #2 in Figure 11

Figure 11, Deflector and Bracket Removal
20. Unmount fuel tank vent tube from mounting bracket and fold toward generator set end.

Figure 12, Fuel Tank Vent Folded Rearward
21. Remove charge air cooler mounting brackets and charge air cooler pipes.

Figure 13, Charge Air Cooler Pipe Removed
22. Remove front side enclosure panels on both sides.

Figure 14, Enclosure Side Panels Removed
23. Remove upper radiator pipe (find #1 in Figure 15 and disconnect radiator vent line ‘T’ (find #2 in Figure 15) and coolant fill hose (find #3 in Figure 15) from radiator.

Figure 15, Radiator Connections to Remove
24. Disconnect lower pipe from radiator

Figure 16, Lower Radiator Pipe
25. Remove engine fan guarding
26. Remove engine fan shroud and slide it back towards engine

Figure 17, Engine Fan Shroud Removed
27. Unmount radiator brackets from trailer frame to remove cooling pack from chassis. Lift up and out.

Figure 18, Cooling Pack Removal
Installation of new cooling package , A077Y449 and Mounting Kit, A078L782 in C500D6RE model generator set
1. Prepare new cooling package for Installation
Note: Coolant level sensor (#2 in Figure 19), and vent line coupler (#1 in Figure 19) may need to be transferred from old cooling pack to the new cooling pack.

Figure 19, Original Parts to Transfer
2. Remove all guards and hoses and pallet mounting brackets that may have shipped on cooling pack.

Figure 20, Shipped with Brackets to Discard
4. Install mounting feet brackets, Part Number A078L782 to new cooling package. Torque bolts to 68Nm [50 ft-lbs].
5. Install new weather stripping on the front, top and sides of new cooling pack frame. Reference old removed cooling package for location if needed.
6. Install new radiator package onto generator set chassis. Torque mounting bolts to 370Nm [273 ft-lbs].
7. Reinstall fan shroud
Note: For customers with radiator package assembly, Part Number A076T598, install new fan shroud, fan guard, CAC and radiator piping.
8. Reinstall fan guard
Note: Guard needs to be mounted all the way up on cooling pack frame to give lower CAC pipe clearance. Apply upward (vertical) pressure when installing.
9. Install lower CAC pipe
10. Install CAC lower bracket
11. Reinstall upper CAC pipe
12. Reinstall lower radiator pipe
13. Reinstall coolant fill hose
14. Reconnect low coolant sensor harness
15. Reinstall upper radiator pipe and vent line
16. Pressure test cooling system to 90 kPa [13 PSI]] with air to check for leaks
17. Once no leaks are confirmed, refill cooling system with coolant
18. Install new cable ties to secure harnesses on fan cage
19. Reinstall side enclosure panels
20. Reinstall lower bracket in front of radiator

21. Reinstall Radiator bulkhead panel
22. Install new flashing piece at base of bulkhead .

Figure 21, New Flashing Installed
23. Reinstall exhaust pipe thru bulkhead with new flange gasket. Torque flange bolts to 115Nm [85 ft-lbs]. Torque exhaust clamps evenly to 68Nm [50 ft-lbs].
Note: Make sure exhaust bellows are not distorted before torquing exhaust connections.
24. Install SCR assembly. Torque shelf mounting bolts to 370Nm [273 ft-lbs].
Note: Take care not to crush/pinch hoses on def tank or dowser
25. Reinstall DEF pump and bracket
26. Install coolant line bracket
27. Reconnect dowser lines
28. Reconnect SCR wiring harness
29. Install cable ties to secure SCR harness
30. Reinstall exhaust with revised exhaust bellow and pipe wrap insulation

Figure 22, Revised Bellow Installed
31. Place top of roof mount onto exhaust
32. Reinstall heat shield
33. Reinstall front crossmember under SCR
34. Reinstall upper crossmember above SCR
35. Reinstall roof
Note: Make sure all-threads have washers between the clamp nuts
36. Reinstall bottom part of exhaust mount with double nuts. Torque to 54Nm [40 ft-lbs].
37. Reinstall fuel tank vent pipe. Torque bolts to 40Nm [30 ft-lbs].
38. Reinstall crankcase vent hose into bulkhead
39. Reinstall cone
40. Seal enclosure panel gaps with UV silicone sealant
End of repair for C500D6RE model generator sets.

Removal of original cooling package, for C1000D6RE model generator sets
Special Tools Needed:
Crane or chain hoist
WARNING
Heavy Load
Incorrect lifting or repositioning can cause severy personal injury or death.
Use a hoist of sufficient capacity for liftin and moving the radiator assembly.
WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Make sure the radiator cap is properly secured before operating the generator set.
1. LOTO unit
2. Drain coolant.
3. Remove the generator set container from the trailer chassis and perform work on flat and level ground.
4. Open the service doors and remove the exhaust discharge roof screen.

Figure 23, Exhaust Discharge Screen Removal
5. Remove SRC and mounting assembly together, leave SCR mounted to the large mounting shelf, and leave shelf mounted to SCR subbase.

Figure 24, SCR and Shelf Assembly Removal
6. Remove radiator shroud and exhaust flange pipe

Figure 25, Radiator Shroud Removal
7. Disconnect all cooling package pipes and hoses.
8. Remove the cooling pack mounting hardware and tilt the cooling package to remove through the roof opening.

Figure 26, Cooling Package Removal
Installation of new cooling package, A077Y449 and Mounting Kit, A078L782 in C1000D6RE model generator set
1. Prepare new cooling package for installation
Note: Coolant level sensor (#2 in figure 26), and vent line coupler (#1 in figure 26) may need to be transferred from old cooling pack to the new cooling pack.

Figure 27, Original Parts to Transfer
2. Remove all guards and hoses and pallet mounting brackets that shipped on cooling pack.

3. Install mounting feet brackets, Part Number A078L782 to new cooling package. Torque bolts to 68Nm [50 ft-lbs].
4. Install new weather stripping on the front, top and sides of new cooling pack frame. Reference old removed cooling package for location if needed.
5. Install new radiator package onto generator set container. Torque mounting bolts to 370Nm [273 ft-lbs].
6. Install all cooling package hose and pipe connections.5.
7. Pressure test cooling system to 90 kPa [13 PSI] with air to check for leaks
8. Once no leaks are confirmed, refill cooling system with coolant7.
9. Reassembly remaining components opposite of how they were removed.
End of repair for C1000D6RE model generator sets.

Warranty Claim Filing Instructions
Note: Warrantable repairs for cooling pack and/or bellow are to be filed separately through the regular warranty process. For repairs outside of warranty, refer to
TSB250166 for C500D6RE models and TSB250167 for C1000D6RE models to determine if unit is covered or not.
Suggested SRTs:
0-901: Technician Admin Time - 0.3 hours
50-401: Steam Clean - 0.4 hours
08-1TL: Cooling Pack- R & I (C500D6RE) - 38.3 hours
99-999: Cooling Pack- R&I (C1000D6RE) - 38.3 hours
99-901: Cooling Pack Upfit and Basin Drain - Qty of 5 (5 hours)
99-008: Cooling Pack Upfit and Basin Drain - 0.3 hours

Service Parts Availability
Service parts are available. See Table 1 for part numbers.
Table 1, Service Parts
Part Description

Existing Part Number

Obsolete

Superseded

New Part Number

Radiator Package

A068H458, A076T598 or
A063P162

N

N

A077Y449

Mounting Kit

N/A

A078L782

Exhaust Bellow*

Order from Girtz

*Exhaust bellow kit is to be ordered from Girtz Industries. Refer to TSB220216 for related part numbers and ordering process.

Document History
Date
2025-4-7

Details
Module Created

Date

Details

2025-4-10

Non-Product Problem Solving (PPS)

2025-8-28

Product Problem Solving (PPS)

Last Modified: 29-Aug-2025