NHTSA ID Number: 10143715
Manufacturer Communication Number: TSB180089-070420
TSB/Document Date: 2018-08-20
Summary
This Technial Service Bulletin is a campaign to replace and repair the old Low Coolant Level (LCL) sensor P/N A042N875 with the new re-design LCL sensor P/N A059E699 and service kit for C150 D2Re/C200 D2Re A059R884, C275 D2Re A059R959 by all authorized technicians.
Campaign # 3315 - Low Coolant Level (LCL) Sensor Service Kit for C150 D2Re, C200 ... Page 1 of 28
Technical Service Bulletin
Technical Service Bulletin:
Released Date: 11-Jul-2018
TSB180089
Campaign # 3315 - Low Coolant Level (LCL) Sensor Service Kit for C150
D2Re, C200 D2Re and C275 D2Re
Campaign # 3315 - Low Coolant Level (LCL)
Sensor Service Kit for C150 D2Re, C200 D2Re
and C275 D2Re
Warranty Statement
The information in this document authorizes specific changes to the repair practice for
failures covered under product warranty coverages.
Contents
Product Affected
• C150 D2Re
• C200 D2Re
• C275 D2Re
Issue
This TSB is a campaign to replace and repair the old LCL sensor P/N A042N875 with the
new re-design LCL sensor P/N A059E699 and service kit for C150 D2Re/C200 D2Re
A059R884, C275 D2Re A059R959 by all authorized technicians.
Resolution
Service tools required for this repair:
•
•
•
•
•
•
Adjustable wrench
Torque wrench
Wire cutters
Crimping tools
Heat gun
Zip tie
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Figure 1, Service Kit
1. Order Service Kit A059R884 for C150 D2Re/C200 D2Re and A059R959 for C275
D2Re through MDC.
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Figure 2, LCL Location
2. Drain system so coolant level is below the LCL sensor and remove existing LCL
Sensor from the radiator surge tank bung.
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Figure 3, Insert New LCL Sensor
3. Insert new LCL Sensor and torque to 14-20 Nm.
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Figure 4, Replace Deutch Connector
4. Cut Deutch connector roughly 3-5 inches from old plug on main wire harness and
insert new kit Deutch connector into new LCL Sensor.
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Figure 5, Splice Main Wire Harness Grey End
5. Splice main wire harness grey end, insert heat shrink and insert into red splice from
sensor so the two grey wires are connected, secure splice (see Figure 19 below).
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Figure 6, Splice Main Wire Harness Purple End
6. Splice main wire harness purple end, insert heat shrink and insert into red splice from
sensor so the blue wires are connected, secure splice (see Figure 19 below).
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Figure 7, Heat Shrink the Sleeves
7. Use heat gun to shrink down heat shrinks and cover them.
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Figure 8, Unplug ECM Connections
8. Move to the ECM connector side of the generator set, unplug OEM connector (for
access) and unplug ECM connector.
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Figure 9, Remove ECM Cover
9. Remove ECM Cover.
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Figure 10, Find 5V Sensor Supply Wire at ECM
10. Find 5V Sensor Supply wire at ECM (Number 8) – See Figure 19.
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Figure 11, Cut 5V Sensor Supply Wire at ECM
11. Cut 5V Sensor Supply wire at ECM (Number 8).
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Figure 12, Splice Ends of 5V Sensor Supply Wire at ECM
12. Splice ends of 5V Sensor Supply wire at ECM (Number 8) and insert heat shrinks.
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Figure 13, Connect White 5V Supply Wire
13. Connect white 5v supply wire (from sensor) to one end of the red 5v Sensor Supply
wire at ECM (Number 8) using blue splice and secure.
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Figure 14, Insert Red End From 5V Sensor Supply Wire
14. Insert remaining red end from 5V Sensor Supply wire at ECM (pin number 8 - see pin
location in Figure 18) to the blue splice and secure.
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Figure 15, Apply Heat to Heat Shrinks
15. Apply heat to heat shrinks (usually with a heat gun).
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Figure 16, Cover and Connect ECM Connector
16. Cover ECM connector and plug it back to the engine, also make sure to connect the
OEM plug back to its original place.
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Figure 17, Zip Tie the Wires to Radiator Guard
17. Use zip ties along radiator fan guard to secure the white wires (5V Supply) from
touching any hot areas on the engine.
18. Fill cooling system with coolant.
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Figure 18, Location of Pin 8 on the OEM Connector
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Figure 19, Connection Wiring Diagram
Service Instruction
Fail Code = OC-TL-OC
Account code: 65
Authorization code: 3175
1 trip allowed
SRTs:
00-602 Administrative Time: 0.7
99-9999 Remove old sensor and installed Repair kit: 1
Fail part: scrapped
Parts:
• A059R884
• A059R959
Service Parts Availability
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The old LCL sensor will be replace by the new LCL sensor. The old sensor will be
removed from the service manual and parts manual and replaced with the new LCL
sensor and service kit. Instructions are located in QSOL literature search.
Service Tools and Training Available
Table 1, Service Parts
Part
Description
Existing Part
Number
Obsolete
Superseded
New Part
Number
Low Coolant
Level Sensor
P/N A042N875
No
yes
P/N A059E699
Service Kit for
C150 D2Re,
C200 D2Re
N/A
N/A
N/A
A059R884
Service kit for
C275 D2Re
N/A
N/A
N/A
A059R959
Implemented for production. See Table 2.
Table 2, Production Information
GSN
Model
Dates
Location
F180373303
R200T4
June 18,2018
Fridley
F180374289
R150T4
June 18,2018
Fridley
F180374464
R275T4
June 18,2018
Fridley
Part Identification
Table 3, C150/C200 D2Re kit A059R884 Contents
F/N
Name
Description
Legacy Name
Qty
1
A059E699
SENSOR,CO
OLANT
LEVEL
A059E699
1
2
A006L207
CONNECTOR
,BUTT
0332-3946-02
1
3
A059R975
SLEEVE,HEA
T SHRINK
A059R975
3
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Table 3, C150/C200 D2Re kit A059R884 Contents
4
A059T273
HARNESS,WI
RING
A059T273
1
5
A059R886
SHEET,INSTR
UCTION
A059R886
1
Table 4, C275 D2Re kit A059R959 Contents
F/N
Name
Description
Legacy Name
Qty
1
A059E699
SENSOR,CO
OLANT
LEVEL
A059E699
1
2
A006L207
CONNECTOR
,BUTT
0332-3946-02
1
3
A059R975
SLEEVE,HEA
T SHRINK
A059R975
3
4
A059T274
HARNESS,WI
RING
A059T274
1
5
A059R886
SHEET,INSTR
UCTION
A059R886
1
Affected Generator Set Serial Numbers
Table 4, Affected Generator Set Serial Numbers
K14076508
9
D16094718
0
A16089006
4
D17018226
0
C17015865
8
L15090554
7
A18031071
9
H17023787
7
A16091565
5
E17018226
1
D16095006
2
B15079073
0
A18030721
3
H17023787
8
A16091663
4
D17017687
2
D16095058
4
B15079932
0
A18030722
4
H17023787
9
A16091565
3
D17017740
7
D16095058
5
K17027933
6
A18030715
7
H17023788
0
A16091560
0
D17017685
1
D16095006
3
K15089285
4
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Table 4, Affected Generator Set Serial Numbers
B18032744
7
F17020294
0
A16091565
4
D17018225
9
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TSB/Document ID: TSB180089-070420
Replacement Service Bulletin Number:
MFR Communication Date: 2018-07-11
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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