NHTSA ID Number: 10144407
Manufacturer Communication Number: TSB180114-082420
TSB/Document Date: 2018-09-17
Summary
This Technical Service Bulletin is a campaign to replace an old Low Coolant Level (LCL) sensor P/N A042N875 with a new redesigned LCL sensor P/N A059E699 and Service Kit for C100 D2Re P/N A060N209 by all authorized technicians.
Campaign # 3475 -Low Coolant level (LCL) sensor Service kit for C100 D2Re
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Technical Service Bulletin
Technical Service Bulletin:
Released Date: 24-Aug-2018
TSB180114
Campaign # 3475 -Low Coolant level (LCL) sensor Service kit for C100 D2Re
Campaign # 3475 -Low Coolant level (LCL)
sensor Service kit for C100 D2Re
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
• C100 D2Re
Issue
This TSB is a campaign to replace an old LCL sensor P/N A042N875 with a new redesigned LCL sensor P/N A059E699 and Service Kit for C100 D2Re P/N A060N209 by
all authorized technicians.
Resolution
Service tools required for this replacement:
•
•
•
•
•
•
Adjustable wrench
Torque wrench
Wire cutter
Crimping tools
Heat gun
Zip tie
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Campaign # 3475 -Low Coolant level (LCL) sensor Service kit for C100 D2Re
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Figure 1, Service Kit Parts
Order Service Kit A060N209 for C100 D2Re through MDC. Verify that the items shown in
Figure 1 are included in the kit.
Make sure the generator set is shut down and disabled, and keep it in the same state
until the coolant temperature reaches normal atmospheric temperature.
a. Move the Rocker Switch to the OFF position to stop the generator set. Allow the
generator set to be thoroughly cool to the touch.
b. Turn off the battery charger. Disconnect the battery charger from the AC source
before disconnecting the cables.
c. Disconnect the negative (-) cable from the battery. Secure the cable so it will not
contact the battery terminals to prevent accidental starting.
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Figure 2, Existing LCL Sensor
Drain system so coolant level is below the LCL sensor. Remove the existing LCL Sensor
from the radiator surge tank bung.
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Figure 3, New LCL Sensor
Install the new LCL sensor. Torque the sensor to 14-20 Nm (10.3-14.7 ft-lb).
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Figure 4, Deutch Connector
Cut the Deutch connector roughly 3-5 inches from old plug on main wire harness. Insert
the new kit Deutch connector into new LCL Sensor.
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Figure 5, Splice Grey End of Main Wire Harness
Splice the grey end of the main wire harness. Insert the heat shrink into the red splice
from the sensor. Make sure that the two grey wires are connected and the splice is
secured.
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Figure 6, Splice Black End of Main Wire Harness
Splice the black end of the main wire harness. Insert the heat shrink into the red splice
from the sensor. Make sure the black wires are connected and the splice is secured.
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Figure 7, Adjust Heat Shrink over Red Splice
WARNING
Heat guns are hot and can cause burns. Avoid touching the hot parts of the heat
gun. Wear protective gear.
Adjust the heat shrink over the red splice connector. Use a heat gun to heat and shrink
the heat shrink.
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Figure 8, ECM and OEM Connectors
Move to the ECM connector side of the generator set. Disconnect the OEM connector
(for access), Disconnect the ECM connector.
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Figure 9, ECM Cover
Remove the ECM Cover.
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Figure 10, 5V Supply Wire
Find the 5V sensor supply wire at ECM connector pin 8. (See figure 18.)
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Figure 11, Cut 5V Sensor Supply Wire
Cut 5V sensor supply wire at ECM (pin 8).
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Figure 12, Splice 5V Sensor Supply Wire
Splice ends of 5V sensor supply wire at ECM (pin 8). Insert heat shrinks.
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Figure 13, Connect Red 5V Supply Wire
Connect the red 5V supply wire (from sensor) to one end of the red 5V sensor supply
wire at ECM (pin 8) using blue splice and secure.
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Figure 14, Connect Red 5V Wire to ECM Pin
Insert remaining red end from 5V sensor supply wire at ECM pin 8 to the blue splice and
secure.
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Figure 15, Adjust Heat Shrink over Blue Splice
WARNING
Heat guns are hot and can cause burns. Avoid touching the hot parts of the heat
gun. Wear protective gear.
Adjust heat shrink over blue splice connector. Use heat gun to apply heat to heat shrink.
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Figure 16, Connect ECM Connector to Engine
Cover the ECM connector and connect it to the engine. Also make sure that the OEM
connector is connected to its original position.
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Figure 17, Route Red Wire
Route the red wire (5V supply) inside the convoluted wire loom that is used for the
existing main wire harness. Use zip ties to make sure the convoluted wire loom (5V
supply) is secured along the radiator fan guard and to prevent the wires from touching
any hot areas.
Refill and top off coolant system with coolant.
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Figure 18, 5V Supply Wire
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Figure 19, Spliced Grey Wire
Service Instruction
Fail Code = OC-TL-OC
Account code: 65
Authorization code: 3475
1 trip allowed
SRTs:
00-602 Administrative Time: 0.7
99-9999 Remove old sensor and install Replacement kit: 1
Fail part: scrapped
Parts:
A060N209
Expiration date: June 19, 2020
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Campaign # 3475 -Low Coolant level (LCL) sensor Service kit for C100 D2Re
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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.
Table 1, Service Parts
Part
Description
Existing Part
Number
Obsolete
Superseded
New Part
Number
Low Coolant
Level Sensor
A042N875
No
Yes
A059E699
Service Kit for
C100 D2Re
-
-
-
A060N209
Parts Identification
Table 2, C100 D2Re Kit A060N209 Contents
F/N
Name
Description
Legacy Name
Qty
1
A059E699
Sensor,
Coolant Level
A059E699
1
2
A006L207
Splice, Butt
0332-3946-02
1
3
A059R975
Sleeve, Shrink
A059R974
3
4
A060N083
Harness,
Wiring
A060N083
1
5
A060P073
Sheet,
Instruction
A060P073
1
Affected Generator set Serial numbers
Table 3, Affected Generator Set Serial Numbers
A180287414
C180339323
D180353835
E180361194
A180288358
C180341659
D180353953
E180361195
A180300973
C180341907
D180353955
E180361234
A180307780
C180342405
D180354191
E180363667
A180307781
C180345016
D180354305
E180363668
A180311216
C180345225
D180354711
E180363905
A180311217
C180345664
D180354712
E180364314
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Table 3, Affected Generator Set Serial Numbers
A180313643
D180348999
E180357326
E180364315
A180313644
D180350622
E180357721
E180368942
A180316108
D180350927
E180357885
E180368943
B180316609
D180351229
E180360471
E180369729
B180316645
D180351653
E180360473
F180369121
B180318731
D180352859
E180360474
I170229858
B180318732
D180353590
E180360719
I170230019
C180332369
D180353591
E180360720
I170230020
C180336449
D180353593
E180361193
Document History
Date
2018-8-21
Details
Module Created
Last Modified: 24-Aug-2018
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TSB/Document ID: TSB180114-082420
Replacement Service Bulletin Number:
MFR Communication Date: 2018-08-24
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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