Installation Procedure on Installing the Oil & Gas Asset IQTM System on All Caterpillar and Non-Caterpillar Diesel, Natural Gas, and Dynamic Gas Blending Engines {1000, 1408, 7620, 7960} Caterpillar

Installation Procedure on Installing the Oil & Gas Asset IQTM System on All Caterpillar and Non-Caterpillar Diesel, Natural Gas, and Dynamic Gas Blending Engines {1000, 1408, 7620, 7960}

Usage:

D3400 01T

Engine: All Gas Engines
Engine Commercial: All Diesel

Introduction

This Special Instruction contains information for installing the Asset IQ^TM System - Oil & Gas on all Caterpillar and non-Caterpillar Diesel, Natural Gas, and Dynamic Gas Blending engines. The Asset IQ^TM System Oil & Gas is used to gather information about the performance of an engine. The system consists of a radio box group and a sensor box group. The sensor box group will gather information from various sensors installed on the engine and will transmit this data, along with diagnostic information to the radio box group to be displayed locally and transmitted to PL web.

Important Safety Information

Do not perform any procedure in this special instruction until this special instruction has been read in entirety, and understood. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe. Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from improper assembly procedures.

Do not attempt any assembly until you have read and understand the assembly instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Working with electrical circuits is hazardous. Bodily contact with electrical potential will cause personal injury or death. Ensure that personnel are trained in proper operating procedures in order to ensure safe operation.

Overview

Applicability

The Asset IQ^TM - Oil & Gas is offered as an aftermarket attachment for use on all diesel, natural gas, and Dynamic Gas Blending engines, both Caterpillar and competitive brands, providing a fleet solution for equipment owners.

Electrical Requirements

This control is designed to operate on 12 or 24 volts DC, negative ground. Current draw of the control package is less than 2.0 amps. External solenoids or other loads driven by the system and connection of a CAT^® Electronic Technician (ET) communications adapter will add to the current draw.

Features

The complete system comes in two boxes. The sensor box group is for attaching all the sensors needed to monitor the engine package. The radio box group which contains a display and all the telematics is to transmit all the data to the local Ethernet and to PL web.

The Asset IQ^TM System - Oil & Gas supports J1939 only protocols for communication with a monitoring and recording device.

Required Parts

Asset IQ^TM System - Oil & Gas Kit Supplied Parts for Installation

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Table 1
538-8656 Installation Group
Qty	Part Number	Part Name
1	533-0540	Box GP (Asset IQ - Sensor)
1	532-8736	Box GP (Asset IQ - Radio)
1	538-8655	Sensor GP - Asset IQ
1	514-1258	Software GP - A3000

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Table 2
481-2111 Install GP - Field (Engine Wiring Group)
Qty	Part Number	Part Name
1	481-2114	Install GP - Field (Engine Speed Sensor)
1	498-5600	Install GP - Field (Ambient Temperature Sensor)
1	481-2112	Install GP - Field (Engine Coolant Temperature Sensor)
1	481-2113	Install GP - Field (Engine Oil Pressure Sensor)
1	498-5601	Install GP - Field (Fuel Pressure Sensor)
1	498-5602	Install GP - Field (Air Intake Pressure Sensor)
1	539-7910	Install GP - Field (Air Inlet Restriction Sensor)
1	498-7472	Install GP - Field (Crankcase Pressure Sensor)
1	498-7473	Install GP - Field (Exhaust Back Pressure Sensor)
2	488-0995	Install GP - Field (Thermocouple - Right Angle)
1	489-3077	Install GP - Field (30L Mounting Hardware)

Additional Parts Need for Installation

Field Fabricated Mounting Brackets

Given the wide range of machines to which the Asset IQ^TM System - Oil & Gas and extra sensors/add-ons can be applied, a standardized mounting method is not possible. Some of the sensors/add-ons will require field fabricated brackets for mounting.

Sensor Hookup Wire

To install the sensors, 136-5321 Cable As ( 9144 cm (300 ft)) will be required. For Installing the 538-8655 Sensor GP, a minimum quantity of ( 9144 cm (300 ft)) will be required for the installation.

Wiring Diagram

Note: During installation, it is important to protect wiring in key locations. Key locations are any area where the wiring could be nicked or cut and come in contact with the chassis. Avoid installation practices where there could be excessive flexing, chafing, or cutting of the wiring.

Asset IQ^TM System - Sensor Box Wiring Diagram

Illustrations 1, 2, 3, 4, 5, 6, 7, 8, and 9 outline all the possible connections to the 533-0540 Asset IQ - Sensor Box.

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Illustration 1	g06257375
Top Half of Asset IQ^TM - Sensor Box Wire Diagram

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Illustration 2	g06257404
Bottom Half of Asset IQ^TM - Sensor Box Wire Diagram

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Illustration 3	g06257425
Asset IQ^TM - Sensor Box Wiring Diagram

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Illustration 4	g06257493
Asset IQ^TM - Sensor Box Wiring Diagram

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Illustration 5	g06257503
Asset IQ^TM - Sensor Box Wiring Diagram

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Illustration 6	g06257509
Sensor Box Wiring Diagram

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Illustration 7	g06257534
Sensor Box Wiring Diagram

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Illustration 8	g06257535
Sensor Box Wiring Diagram

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Illustration 9	g06257536
Sensor Box Wiring Diagram

Illustration 10 outlines the connections to the 532-8736 Asset IQ - Radio Box

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Illustration 10	g06257545
Asset IQ^TM - Sensor Box Wiring Diagram

Installation

Engine Preparation

Stop the engine.
Follow all Lock Out/Tagged Out Procedures.

Installation of the Asset IQ^TM - Sensor Box

Due to the variable options, mounting of the Asset IQ^TM Sensor Box is left to the discretion of the installer. Use the following requirements to fabricate any brackets required for mounting the Sensor Box in a location that meets the following requirements.

Access to battery (+).
Access to battery (-).
Access to keyswitch as supplied by the ignition system. If keyswitch is unavailable, use battery (+ ) power.
Access to the main data link(s) on the engine.
Do not mount the sensor box on the engine because of excessive vibration.

Installation of the Asset IQ^TM - Radio Box

Due to the variable options, mounting of the Asset IQ^TM Sensor Box is left to the discretion of the installer. Use the following requirements to fabricate any brackets required for mounting the Radio Box in a location that meets the following requirements.

Access to battery (+).
Access to battery (-).
Access to keyswitch as supplied by the ignition system. If keyswitch is unavailable, use battery + power.
Position the radio box less than 50 routed wiring feet from the sensor box.
Note: Must be located where the display is safely accessible while the engine is running.
Must be located where the antenna can be routed to an unobstructed view of the sky. Refer to Special Instruction , REHS8850 and REHS9111 for the antenna installation.
Once the antenna is mounted, route the coaxial cable back to the radio box and inside to connect to the preinstalled radio.
Note: During installation, it is important to protect wiring in key locations. Key locations are any area where the wiring could be nicked or cut and come in contact with the chassis. Avoid installation practices where there could be excessive flexing, chafing, or cutting of the wiring.

Configuration of the Installed System

Each Asset IQ^TM System - Oil & Gas will come from the manufacturer with the software flashed into the Electronic Control Module (ECM) and the system configuration already loaded into the ECM.

Electrical Validation of the Installed System

Power On Tests

Power, Ground, Keyswitch Connections Test

Connect power, ground, and keyswitch.
Connect a digital volt meter negative lead to the chassis.
With the power OFF connect a digital volt meter positive lead to terminal block 27B. The resistance should be less than 3 ohms and no voltage present.
With the power ON connect a digital volt meter positive lead to terminal block 27B. The expected result is battery voltage.
With the power ON and the key switch OFF, connect a digital volt meter positive lead to terminal block 27A. The expected result is close to zero volts.

Communications Link Connections Test

Turn the keyswitch to the ON position.
Connect Cat ET adapter to A-C7 CAN A. Set protocol option to J1939.
Using Cat ET, verify that three ECMs are detected.
Read Cat ET status screen to check that the ECM is reporting the ECM part number and serial number, software group part number, release date, and description.
Verify that there are no errors being reported.

Asset IQ^TM Basic Sensor Options

This section will describe the available basic sensor options for the Asset IQ^TM system.

481-2112 Temperature Sensor Gp (Coolant)

This group is for use with the Asset IQ^TM System to monitor the engine coolant temperature.

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Table 3
481-2112 Temperature Sensor Gp (Coolant)
Qty	Part Number	Part Name
1	3K-0360	O-Ring Seal
4	9X-3402	Connector Socket
1	133-0969	Socket Connector
1	155-2261	Plug Lock Wedge
1	155-2269	Connector Plug As
1	264-4297	Temperature Sensor

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Illustration 11	g06257741
Coolant Pressure Sensor

Note: To install the temperature sensor, order the 136-5321 Cable As (Bulk).

Install 3K-0360 O-Ring Seal onto 264-4297 Temperature Sensor.
Locate an unused temperature port on the engine block and install 264-4297 Temperature Sensor. Tighten to 20 ± 3 N·m (15 ± 2 lb ft).
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Red and Drain wire. Install 9X-3402 Connector Sockets on the white and black wires. Install sockets into 155-2269 Connector Plug As.
Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Cut off the red wire. Install the black wire into terminal block 38C and install the white wire into terminal block 38A. Install the drain wire into terminal 5 of the chassis ground bus. Refer to Illustration 11 for the correct location of the wires.

481-2113 Pressure Sensor Gp (Oil)

This group is for use with the Asset IQ^TM System to monitor the engine oil pressure.

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Table 4
481-2113 Pressure Sensor Gp (Oil)
Qty	Part Number	Part Name
1	6V-9028	O-Ring Seal
6	9X-3402	Connector Socket
1	133-0969	Socket Connector
1	281-8804	Connector Plug As
1	320-3060	Pressure Sensor Gp

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Illustration 12	g06257784
Oil Pressure Sensor

Note: To install the pressure sensor, order 136-5321 Cable As (Bulk).

Install 6V-9028 O-Ring Seal onto 274-6719 Pressure Sensor Gp.
Locate an unused oil pressure port on the engine block and install 274-6719 Pressure Sensor Gp. Tighten to 10 ± 2 N·m (7 ± 1 lb ft).
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed drain wire. Install 9X-3402 Connector Sockets on the red, black, and white wires. Install sockets into 281-8804 Connector Plug As.
Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Install the red wire into terminal block 37B, install the black wire into terminal block 37C, and install the white wire into terminal block 37A. Install the drain wire into terminal 4 of the chassis ground bus. Refer to Illustration 12 for the correct location of the wires.

481-2114 Speed Sensor Gp (Engine)

This group is for use with the Asset IQ^TM System to monitor the engine speed without fuel flow system.

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Table 5
481-2114 Speed Sensor Gp (Engine)
Qty	Part Number	Part Name
4	9X-3402	Connector Socket
1	133-0969	Socket Connector
1	155-2269	Connector Plug As
1	455-2261	Plate
1	318-1181	Speed Sensor Gp

Note: To install the engine speed sensor, order 136-5321 Cable As (Bulk).

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Illustration 13	g06257821
Speed Sensor (1) 0.5 mm (0.020 inch) to 1 mm (0.04 inch) Air Gap

Remove plug in flywheel housing and install 318-1181 Speed Sensor Gp. Screw in sensor until sensor contacts flywheel. After the speed sensor contacts the flywheel, back the speed sensor out one full turn and tighten jam nut to 25 ± 5 N·m (18 ± 4 lb ft).
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Illustration 14 g06257876

Engine Speed Sensor
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed red and drain wire. Install 9X-3402 Connector Sockets on the black and white wires. Install sockets into 155-2269 Connector Plug As.
Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Cut off the red wire. Install the black wire into terminal block 30C and install the white wire into terminal block 30A. Install the drain wire into terminal 1 of the chassis ground bus. Refer to Illustration 14 for the correct location of the wires.

498-5600 Temperature Sensor Gp (Ambient)

This group is for use with the Asset IQ^TM system to monitor the ambient air temperature.

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Table 6
498-5600 Temperature Sensor Gp (Ambient)
Qty	Part Number	Part Name
1	2P-1279	Locknut
1	3J-1907	O-Ring Seal
1	8T-8737	Seal Plug
6	9X-3402	Connector Socket
1	102-8804	Receptacle Kit
1	133-0969	Socket Connector
1	230-5008	Connector Plug As
1	288-8390	Temperature Sensor Gp

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Illustration 15	g06257889
Ambient Temperature Sensor

Note: To install the temperature sensor, order 136-5321 Cable As (Bulk). Also, fabricate a bracket for the temperature sensor. The mounting location needs to be in a location off the engine and out of the flow of hot or cold air flow directly on the sensor.

Install 3J-1907 O-Ring Seal onto 288-8390 Temperature Sensor Gp.
Install 288-8390 Temperature Sensor Gp onto field fabricated bracket and install 2P-1279 Locknut. Tighten to 20 ± 5 N·m (15 ± 4 lb ft).
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed drain wire and shielding. Install 9X-3402 Connector Sockets on the red, black, and white wires. Install sockets into 230-5008 Connector Plug As.
Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as need of the harness jacket. Install the red wire into terminal block 31B, install the black wire into terminal block 31C, and install the white wire into terminal block 31A. Install the drain wire into terminal 2 of the chassis ground bus. Refer to Illustration 15 for the correct location of the wires.

498-5601 Pressure Sensor Gp (Fuel)

This group is for use with the Asset IQ^TM System to monitor the engine fuel pressure.

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Table 7
498-5601 Pressure Sensor Gp (Fuel)
Qty	Part Number	Part Name
6	9X-3402	Connector Socket
1	133-0969	Socket Connector
1	155-2267	Connector Plug As
1	155-2276	Plug Lock Wedge
1	216-8684	Pressure Sensor Gp

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Illustration 16	g06257945
Fuel Pressure Sensor

Note: To install the pressure sensor, order 136-5321 Cable As (Bulk).

Locate a port after the fuel filters and install 216-8684 Pressure Sensor Gp. Tighten to 10 ± 2 N·m (7 ± 1 lb ft).
Cut a 7.62 m (25 ft) or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed drain wire. Install 9X-3402 Connector Sockets on the red, black, and white wires. Install sockets into 155-2267 Connector Plug As.
Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Install the red wire into terminal block 32B, install the black wire into terminal block 32C, and install the white wire into terminal block 32A. Install the drain wire into terminal 3 of the chassis ground bus. Refer to Illustration 16 for the correct location of the wires.

Air Intake Pressure Sensor Kit (In or Out Press) and 498-5602 Pressure Sensor Gp (Air)

This group is for use with the Asset IQ^TM System to monitor the engine oil pressure.

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Table 8
498-5602 Pressure Sensor Gp (Air)
Qty	Part Number	Part Name
6	9X-3402	Connector Socket
1	133-0969	Socket Connector
1	281-8803	Connector Plug As
1	305-6873	Pressure Sensor Gp

Note: To install the sensor, you will need to order 136-5321 Cable As (Bulk).

Installing Air Intake Pressure Sensor (In or Out)

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Illustration 17	g06257956
Air Intake Pressure Sensor (In)

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Illustration 18	g06257958
Air Intake Pressure Sensor (Out)

Locate a port before or after the engine intercooler and install 305-6873 Pressure Sensor Gp. Tighten to 10 ± 2 N·m (7 ± 1 lb ft).
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed drain wire. Install 9X-3402 Connector Sockets on the red, black, and white wires. Install sockets into 281-8803 Connector Plug As.
Air Intake Pressure Sensor (In) Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Install the red wire into terminal block 39B, install the black wire into terminal block 39C, and install the white wire into terminal block 39A. Install the drain wire into terminal 6 of the chassis ground bus. Refer to Illustration 17 for the correct location of the wires.
Air Intake Pressure Sensor (Out) Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Install the red wire into terminal block 43B, install the black wire into terminal block 43C, and install the white wire into terminal block 43A. Install the drain wire into terminal 10 of the chassis ground bus. Refer to Illustration 18 for the correct location of the wires.

Installing Air Intake Restriction Sensor

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Illustration 19	g06257962
Air Intake Restriction Sensor

Locate a port just after the air intake filter and install 305-6873 Pressure Sensor Gp. Tighten to 10 ± 2 N·m (7 ± 1 lb ft).
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed drain wire. Install 9X-3402 Connector Sockets on the red, black, and white wires. Install sockets into 281-8803 Connector Plug As.
Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Install the red wire into terminal block 41B, install the black wire into terminal block 41C, and install the white wire into terminal block 41A. Install the drain wire into terminal 8 of the chassis ground bus. Refer to Illustration 19 for the correct location of the wires.

498-7472 Pressure Sensor Gp (Crankcase)

This group is for use with the Asset IQ^TM System to monitor the crankcase pressure.

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Table 9
498-7472 Pressure Sensor Gp (Crankcase)
Qty	Part Number	Part Name
1	6V-6560	O-Ring Seal
6	9X-3402	Connector Socket
1	133-0969	Socket Connector
1	237-0227	Connector Plug As
1	274-6720	Pressure Sensor Gp

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Illustration 20	g06257969
Crankcase Pressure Sensor

Note: To install the pressure sensor, order 136-5321 Cable As (Bulk).

Install 6V-6560 O-Ring Seal onto 274-6720 Pressure Sensor Gp.
Locate a port on the side of the engine block and install 274-6720 Pressure Sensor Gp. Tighten to 10 ± 2 N·m (7 ± 1 lb ft).
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed drain wire. Install 9X-3402 Connector Sockets on the red, black, and white wires. Install sockets into 237-0227 Connector Plug As.
Route the harness back to Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Install the red wire into terminal block 42B, install the black wire into terminal block 42C, and install the white wire into terminal block 42A. Install the drain wire into terminal 9 of the chassis ground bus. Refer to Illustration 20 for the correct location of the wires.

498-7473 Pressure Sensor Gp (Exhaust Back Pressure)

This group is for use with the Asset IQ^TM System to monitor the Exhaust Back Pressure.

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Table 10
498-7473 Pressure Sensor Gp (Exhaust Back Pressure)
Qty	Part Number	Part Name
7	9X-3402	Connector Socket
61 cm (24 inch)	122-6870	Hydraulic Hose (#8 Hose)
2	185-1047	Adapter (Hose Barb)
1	228-7100	O-Ring Seal
1	281-8803	Connector Plug As
1	330-6719	Pressure Sensor Gp
2	359-7325	Hose Clamp
1	467-3156	Boss
1	N/A	M12.5X1.5 STOR F X M12.5X1.5 STOR F Coupling⁽¹⁾

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⁽¹⁾	The M12X1.5 STOR x M12X1.5 STOR Female to Female Coupling is to be selected by the customer.

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Illustration 21	g06257974
Exhaust Back Pressure Sensor

Note: To install the exhaust back pressure sensor , order 136-5321 Cable As (Bulk).

Install 228-7100 O-Ring Seal onto 330-6719 Pressure Sensor Gp.
Cut a hole in the exhaust stack and install the 467-3156 Boss. Assemble the 185-1047 Adapter (Hose Barb) and the 359-7325 Hose Clamp to each end of the 122-6870 Hydraulic Hose (#8 Hose). Attach the hose assembly to the weld boss. Attach XXX-XXXX Hose Coupling to the end of the hose assembly and attach the 330-6719 Pressure Sensor Gp to the house coupling. Locate the sensor above the weld boss to prevent moisture from entering into the sensor.
Cut a 7.62 m (25 ft) piece or as needed from 136-5321 Cable As (Bulk). On one end remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed drain wire. Install 9X-3402 Connector Sockets on the red, black, and white wires. Install sockets into 237-0227 Connector Plug As.
Route the harness back to the Asset IQ^TM ECM. Remove excess wire and remove 38 mm (1.5 inch) or as needed of the harness jacket. Install the red wire into terminal block 40B, install the black wire into terminal block 40C, and install the white wire into terminal block 40A. Install the drain wire into terminal 7 of the chassis ground bus. Refer to Illustration 21 for the correct location of the wires.

Asset IQ^TM Fuel Flow Options

For ordering and installation information, refer to Special Instruction, REHS8848.

Asset IQ^TM Exhaust Port Temperature Monitoring option

For ordering and installation information, refer to Special Instruction, M0069642.

Fluid Property Sensor Option

For ordering and installation information, refer to Special Instruction, M0077650.

RTD Module Option

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Table 11
RTD Installation Gp
Part Number	Part Name
543-4555	Sensor Kit
543-4556	Sensor Kit
543-4557	Sensor Kit
543-4558	Sensor Kit
543-4559	Sensor Kit
543-4560	Sensor Kit

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Table 12
Compression Fittings for use with RTD Installation
Part Number	RTD Probe Size	Boss Fitting Size
514-3797	1/4 inch diameter	1/4 inch NPT
514-3798	1/4 inch diameter	1/8 inch NPT
514-3799	1/8 inch diameter	1/4 inch NPT
514-3800	1/8 inch diameter	1/8 inch NPT

Raw Water RTD

Raw Water Inlet RTD

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Illustration 22	g06287760

Locate the boss on the Raw Water Inlet side of the Oil Heat Exchanger. Select the required RTD and Compression Fitting from the above tables. Remove the plug from the Inlet boss and install the compression fitting with the RTD probe.
Cut a 7.62 m (25 ft) piece or as needed from 481-2115 Cable As (Bulk Cable). On one end, remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Drain wire. Install the 9X-3402 Connector Sockets on the Red, Black, and White wires. Install the sockets into the 269-8222 Connector Plug As and the 155-2276 Plug Lock Wedge as shown in the schematic.
Route the harness back to the Asset IQ^TM ECM. Remove the excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Install the Red wire into terminal block 07B, install the Black wire into terminal block 07C, and install the White wire into terminal block 07A. Install the Drain wire into terminal 17 of the Chassis Ground Bus. Use the schematic above as a guide.

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Illustration 23	g06287761

Locate the boss on the Raw Water Outlet side of the Oil Heat Exchanger. Select the required RTD and Compression Fitting from the above tables. Remove the plug from the Outlet boss and install the compression fitting with the RTD probe.
Cut a 7.62 m (25 ft) piece or as needed from 481-2115 Cable As (Bulk Cable). On one end, remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Drain wire. Install the 9X-3402 Connector Sockets on the Red, Black, and White wires. Install the sockets into the 269-8222 Connector Plug As and the 155-2276 Plug Lock Wedge as shown in the schematic.
Route the harness back to the Asset IQ^TM ECM. Remove the excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Install the Red wire into terminal block 08B, install the Black wire into terminal block 08C, and install the White wire into terminal block 08A. Install the Drain wire into terminal 18 of the Chassis Ground Bus. Use the schematic above as a guide.

Water Temperature RTD

Water Inlet RTD

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Illustration 24	g06287765

Locate the boss on the Water Inlet side of the Air Intake Cooler. Select the required RTD and Compression Fitting from the above tables. Remove the plug from the Inlet boss and install the compression fitting with the RTD probe.
Cut a 7.62 m (25 ft) piece or as needed from 481-2115 Cable As (Bulk Cable). On one end, remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Drain wire. Install the 9X-3402 Connector Sockets on the Red, Black, and White wires. Install the sockets into the 269-8222 Connector Plug As and the 155-2276 Plug Lock Wedge as shown in the schematic.
Route the harness back to the Asset IQ^TM ECM. Remove the excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Install the Red wire into terminal block 01B, install the Black wire into terminal block 01C, and install the White wire into terminal block 01A. Install the Drain wire into terminal 11 of the Chassis Ground Bus. Use the schematic above as a guide.

Water Outlet RTD

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Illustration 25	g06287767

Locate the boss on the Water Outlet side of the Air Intake Cooler. Select the required RTD and Compression Fitting from the above tables. Remove the plug from the Outlet boss and install the compression fitting with the RTD probe.
Cut a 7.62 m (25 ft) piece or as needed from 481-2115 Cable As (Bulk Cable). On one end, remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Drain wire. Install the 9X-3402 Connector Sockets on the Red, Black, and White wires. Install the sockets into the 269-8222 Connector Plug As and the 155-2276 Plug Lock Wedge as shown in the schematic.
Route the harness back to the Asset IQ^TM ECM. Remove the excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Install the Red wire into terminal block 02B, install the Black wire into terminal block 02C, and install the White wire into terminal block 02A. Install the Drain wire into terminal 18 of the Chassis Ground Bus. Use the schematic above as a guide.

Oil Temperature RTD

Oil Inlet RTD

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Illustration 26	g06287781

Locate the boss on the Oil Inlet side of the Oil Heat Exchanger. Select the required RTD and Compression Fitting from the above tables. Remove the plug from the Inlet boss and install the compression fitting with the RTD probe.
Cut a 7.62 m (25 ft) piece or as needed from 481-2115 Cable As (Bulk Cable). On one end, remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Drain wire. Install the 9X-3402 Connector Sockets on the Red, Black, and White wires. Install the sockets into the 269-8222 Connector Plug As and the 155-2276 Plug Lock Wedge as shown in the schematic.
Route the harness back to the Asset IQ^TM ECM. Remove the excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Install the Red wire into terminal block 03B, install the Black wire into terminal block 03C, and install the White wire into terminal block 03A. Install the Drain wire into terminal 13 of the Chassis Ground Bus. Use the schematic above as a guide.

Oil Outlet RTD

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Illustration 27	g06287814

Locate the boss on the Oil Outlet side of the Oil Heat Exchanger. Select the required RTD and Compression Fitting from the above tables. Remove the plug from the Inlet boss and install the compression fitting with the RTD probe.
Cut a 7.62 m (25 ft) piece or as needed from 481-2115 Cable As (Bulk Cable). On one end, remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Drain wire. Install the 9X-3402 Connector Sockets on the Red, Black, and White wires. Install the sockets into the 269-8222 Connector Plug As and the 155-2276 Plug Lock Wedge as shown in the schematic.
Route the harness back to the Asset IQ^TM ECM. Remove the excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Install the Red wire into terminal block 04B, install the Black wire into terminal block 04C, and install the White wire into terminal block 04A. Install the Drain wire into terminal 14 of the Chassis Ground Bus. Use the schematic above as a guide.

Air Intake Temperature RTD (Before Heat Exchanger)

Air Intake Inlet RTD

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Illustration 28	g06287822

Locate the boss on the Air Intake Inlet side of the Air Intake Heat Exchanger. Select the required RTD and Compression Fitting from the above tables. Remove the plug from the Inlet boss and install the compression fitting with the RTD probe.
Cut a 7.62 m (25 ft) piece or as needed from 481-2115 Cable As (Bulk Cable). On one end, remove 38 mm (1.5 inch) of the jacket and shielding. Cut off exposed Drain wire. Install the 9X-3402 Connector Sockets on the Red, Black, and White wires. Install the sockets into the 269-8222 Connector Plug As and the 155-2276 Plug Lock Wedge as shown in the schematic.
Route the harness back to the Asset IQ^TM ECM. Remove the excess wire and remove 152.4 mm (6 inch) or as needed of the harness jacket. Install the Red wire into terminal block 05B, install the Black wire into terminal block 05C, and install the White wire into terminal block 05A. Install the Drain wire into terminal 15 of the Chassis Ground Bus. Use the schematic above as a guide.