NHTSA ID Number: 10043817
Manufacturer Communication Number: 54-265
TSB/Document Date: 2012-04-27
Summary
FREIGHTLINER
: THE TREE-WIRE LOW COOLANT LEVEL SENSOR (CAS 700685 001) ON SOME M2 VEHICLES BUILT FROM 2007 TO OCTOBER 8, 2009, WITH CUMMINS ISB AND ISC ENGINES, MAY DEVELOP AN INTERNAL LEAK CAUSING THE ENGINE LIGHT TO ILLUMINATE AND THE ENGINE TO SHUT DOWN. *JS
SB-10043817-3174
Cummins ISB and ISC, Low Coolant Level Sensor
Conversion
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional
Century Class Conventional
Argosy COE
Cargo
Columbia
54-265
Freightliner
Service Bulletin
Coronado
> Business Class M2
Cascadia
108SD/114SD
General Information
The three-wire low coolant level sensor (CAS 700685 001) on some M2 vehicles built from 2007 to October 8,
2009, with Cummins ISB and ISC engines, may develop an internal leak, causing the engine light to illuminate
and the engine to shut down. The wire connectors to the sensor may also become corroded. A new two-wire
sensor (KYS 5022 11366 05) with a harness (A06-66670-012) and module (KYS 1539 10206 03), is available to
replace this part.
Follow the instructions below to replace the sensor.
Replacement
1. Park the vehicle on a level surface, shut down the engine and set the parking brakes. Chock the tires.
2. Drain the coolant from the cooling system enough to get it below the level of the low coolant level sensor.
3. Disconnect the batteries.
4. Disconnect the wire harness from the sensor.
5. Remove the sensor from the surge tank. See Fig. 1.
2
1
3
01/27/2012
1. Surge Tank
2. Sensor
f545871
3. Wire Harness
Fig. 1, Low Coolant Level Sensor Installation
6. Inspect the wiring harness connector terminals for signs of corrosion. Clean or replace the connector as
needed.
7. Install the new two-wire sensor in the surge tank.
8. Mount the module to the frontwall using an unused stud near the horns. See Fig. 2.
9. Connect the new wire harness to the original low coolant sensor connector, the module, and the new
sensor. Secure the new harness to the existing wiring with zip ties as needed. See Fig. 3 for replacement
parts.
10. Connect the batteries.
11. Fill the cooling system with coolant, and check for leaks.
Freightliner Service Bulletin, February 2012
Page 1
Cummins ISB and ISC, Low Coolant Level Sensor
Conversion
54-265
Freightliner
Service Bulletin
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional
Century Class Conventional
Argosy COE
Cargo
Columbia
Coronado
> Business Class M2
Cascadia
108SD/114SD
2
3
1
1
2
3
01/27/2012
01/27/2012
f545872
1. Jumper Harness
2. Module
f545873
1. Module
2. Jumper Harness
3. New Sensor
3. Stud
Fig. 3, Replacement Sensor, Harness and Module
Fig. 2, New Module Installation
Parts
Parts are available through the PDC. See Table 1 for replacement parts.
Low Coolant Level Sensor Replacement Parts
Original Part
Replacement Parts
Part Number
Description
Part Number
Description
KYS 5022 11366 05 Low Coolant Level Sensor 2-Wire
CAS 700685 001 Low Coolant Level Sensor, 3-Wire
A06-66670-012
Harness
KYS 1539 10206 03 Module
Table 1, Low Coolant Level Sensor Replacement Parts
Warranty
This procedure is warrantable one time only per vehicle, and only if the described condition exists and the repair is performed within the applicable base or extended coverage warranty period. If a failure is not found, this
procedure is considered preventive and warranty does not apply.
Normal warranty applies. See Table 2 for QuickClaim damage code and labor allowance information. Refer to
this service bulletin by number at the beginning of the claim comments. See Table 3 for OWL VMRS codes and
labor allowance information. Enter this service bulletin number in the Service Bulletin #: field.
Damage Code
152-007548609
SRT Code
152-5025A
QuickClaim Damage Code and Labor Allowance
Description
Sensor, Low Coolant Level, R/R
Time: Hours
0.7
Table 2, QuickClaim Damage Code and Labor Allowance
Page 2
Freightliner Service Bulletin, February 2012
Cummins ISB and ISC, Low Coolant Level Sensor
Conversion
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional
Primary Failed Part
CAS 700685 001
Century Class Conventional
Argosy COE
Cargo
Columbia
Coronado
> Business Class M2
Cascadia
108SD/114SD
OWL VMRS Codes and Labor Allowance
Component
Cause Code SRT Code
Description
Code
003-001-052
18
152-5025A Sensor, Low Coolant Level, R/R
54-265
Freightliner
Service Bulletin
Time: Hours
0.7
Table 3, OWL VMRS Codes and Labor Allowance
Freightliner Service Bulletin, February 2012
Page 3
- Contains Alugard Plus for compatibility with all ethylene...
- Fights corrosion, scaling and rust while protecting all...
- High-quality additives protect against leaks and won’t...
- Pre-mixed yellow formula is ready-to-use in a 50/50 ratio...
- Contains 30 – 50 ppm of denatonium benzoate as a bittering...
- 5 year/150, 000 mile . Silicate-free, long-life, phosphate...
- Formulated to replace the OEM fluid in Asian make vehicles...
- The long life formula provides protection for all cooling...
- Meets the following OEM and industry specifications...
- Contains 30 – 50 ppm of denatonium benzoate as a bittering...
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TSB/Document ID: 54-265
Replacement Service Bulletin Number:
MFR Communication Date: 2012-02-01
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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