Instructions for Installing AssetIQ<SUP>TM</SUP> for Commercial Generator Set Systems on Caterpillar and non-Caterpillar Products {4450, 7490} Caterpillar


Instructions for Installing AssetIQTM for Commercial Generator Set Systems on Caterpillar and non-Caterpillar Products {4450, 7490}

Usage:

SR4B 1BN


Electric Power Generation
All

Introduction

This Special Instruction contains information for installing the AssetIQTM for commercial generator set systems on Caterpillar and non-Caterpillar products. The system consists of an ECM and harness used to monitor the 3-phase voltage and current from the generator, maintain a service hour meter, and detect and report battery voltage. The data are:

  • Generator voltage

  • Battery voltage

  • Generator frequency

  • Engine service hours (diagnostic clock)

  • Generator current

The system also provides support for optional sensors including an engine speed MPU sensor, an engine oil pressure sensor, and an engine coolant temperature sensor, creating a scalable solution to electronic generator set monitoring.

The system will report this data, along with any diagnostic information, on the main data link to be received by a recording ECM such as Product Link.

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 also 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 in order 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.

------ WARNING! ------

Personal injury or death can result from improper assembly procedures.

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


------ WARNING! ------

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.


------ DANGER! ------

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.


Electrostatic Discharge Awareness


NOTICE

ECM control contains components that are sensitive to ELECTROSTATIC DISCHARGE (ESD). An electrostatic charge can damage the control resulting in EMCP 4 breakdown or improper operation. Take the following precautions while installing/removing/handling the control.


  • Handle equipment correctly. Use ESD protective packaging and material handling containers that are anti-static and provide discharge protection and electric field suppression.

  • Use protective devices. ESD - protective workstations and/or work surfaces that include a grounding mat anti-static wrist strap.

  • Keep all plastic items away from the devices. Any plastic item is a potential static generator. The plastic includes candy wrappers, foam cups, synthetic carpet, and foam cushions.

  • The anti-static bag cannot function as a static dissipating mat.

  • DO NOT use an anti-static bag for any other purpose than to enclose a product.

The 70-pin connector on the back of the control is the most vulnerable area to electrostatic discharge (ESD). Extra attention to the back of the control is necessary when handling the EMCP control. The control may become damaged or inoperable if extra care is not taken.

Consult the Electrostatic Discharge Association for proper procedure during particular situations at: http://www.esda.org.

System Overview



Illustration 1g03836662
System diagram
(1) Fuel flow monitoring (not included in kit)
(2) Product Link PL522 (not included in kit)
(3) J1939 (CAN) output for Cat ET
(4) Engine speed MPU
(5) Engine oil pressure sensor
(6) Engine coolant temperature sensor
(7) Generator phase current transformers (not included in kit)
(8) 3-phase voltage current transformers feed directly into ECM (600 V max)

Applicability

The AssetIQTM Generator Set System is offered for use on a generator set, for both Caterpillar and non-Caterpillar brands. This kit can be retrofitted to many brands and types of equipment, and is offered as an aftermarket attachment, potentially providing a fleet solution for equipment owners.

Electrical Requirements

This control is designed to operate on 12 VDC or 24 VDC which will hereafter be referred to as BAT (+) and BAT (-). Current draw of the control package is less than 2 A.

Remote Monitoring Requirements

Remote monitoring requires a telematics system, such as Product Link, to be installed on the system that will transmit the data off board. Refer to Special Instruction and Application and Installation publications for the Product Link device to be used with this kit.

Features

The AssetIQTM generator set system kit provides or enhances the minimum functionality to a mechanical generator set engine system. Installation of this kit will allow support for electronic monitoring by:

  • reading and reporting generator voltage

  • calculating and reporting generator frequency

  • reading and reporting generator current

  • reading and reporting the battery voltage

  • maintaining and reporting a service hour meter

Installation of optional sensors provides additional functionality. This additional support currently includes:

  • reading and reporting engine speed using an optional magnetic pick-up sensor

  • reading and reporting oil pressure using an optional active PWM analog sensor

  • reading and reporting coolant temperature using an optional passive analog resistance sensor

Table 1
Engine Parameters as shown in Caterpillar Electronic Technician (Cat ET) 
Parameter  Unit 
Engine Oil Pressure  kpa 
Engine Coolant Temperature  Degrees C 
Battery Voltage 
Engine Speed  rpm 
Diagnostic Clock  hours 
Generator Average Line AC RMS Voltage  Va 
Generator AC Frequency  Hz 
Generator Overall Power Factor  N/A 
Generator Overall Power Factor Lagging  N/A 
Generator Total Real Power  kW 
Generator Total Apparent Power  kW 

Installation

Preparing the Engine

  1. The engine must be on a smooth, level surface that will support the weight of the engine.

  2. Turn OFF the engine with the KEY switch to the OFF position.


    Illustration 2g00104545

  3. Use proper Lock out and Tag out procedures. Attach a "Do Not Operate" warning tag to the engine start switch or the controls before you perform any service to the engine. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar Dealer.

Parts List

Note: All the parts in Table 2 can be ordered individually.

Table 2
Contents of 481-2120 Generator Installation Group (AssetIQTM) 
Qty  Part Number  Description 
481-2127  Generator Set Control Group 
355-9019  Generator Set Electronics Group 
6V-8490  Bolt 
208-8469  Locknut 
12  9X-8256  Washer 
457-1577  Control Harness Assembly 
469-1993  Film 
100  3S-2093  Cable Strap 
458-2064  Wiring Diagram 
155-2269  Connector Plug Assembly 
9X-3402  Connector Socket 
155-2261  Plug Lock Wedge 
469-1993  Film 
Optional Components 
481-2121  Electrical Installation Group 
481-2122  Field Installation Group 
481-2123  Coolant Temperature Sensor Group 
481-2124  Oil Pressure Sensor Group 
481-2125  Speed Sensor Group 
481-2115  Cable Assembly 

Installation of Electronic Control Module (ECM)



Illustration 3g03837116
ECM mounting dimensions

Depending upon the mounting location, it may be necessary to fabricate a bracket to mount to the ECM. Refer to Illustration 3 to fabricate a bracket for the ECM in a location that meets these requirements:

  • Access to a fused source of Bat (+) power

  • Access to Bat (-)

  • Access to the main data link(s) on the engine

  • Mounting the ECM on the engine is not allowed due to the excessive vibration

The hardware for mounting the ECM provided in the kit are listed in Table 3.

Table 3
ECM Mounting Hardware 
Qty  Part Number  Part Name  Description 
6V-8490  Bolt  Bolt, M6×1.0×25, Hex Head 
208-8469  Locknut  Hex, Nylock, M6×1.0 
12  9X-8256  Washer  Washer, Flat, 6.6 ID×12.0 OD×2.0 T 

Perform the following procedure for installing the ECM:

  1. There are six mounting points on the plate to which the ECM is attached. Drill a hole to accommodate a size M6 bolt that corresponds to each mounting point.

  2. Use a 6V-8490 Bolt, two 9X-8256 Washers, and a 208-8469 Locknut at each mounting location of the ECM.

Electrical Wiring Diagrams

Main Wiring Harness



Illustration 4g03837140
Main wiring harness schematic


Illustration 5g03837142
Main wiring harness current and voltage generator schematic

The main harness schematic, shown in Illustration 4 and Illustration 5, is included with the 457-1577 Control Harness Assembly.

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.

Generator Voltage Harness



Illustration 6g03837145
Generator voltage harness wiring diagram
(9) 457-1578 Wiring Harness
(10) Location for installing fuses

Due to the variations in length requirements, the generator voltage harness must be assembled at installation, as shown in Illustration 6, using the components that have been provided in the kit, as listed in Table 4. This harness will connect to connector "E-C12" as shown in the Illustration 5.

Note: Install the fuses near generator output tabs and keep wiring, on unprotected side of fuses, short. Refer to Illustration 6.

Table 4
481-2121 Electrical Installation Group (Gen Voltage Harness) 
Qty  Part Number  Part Name  Description 
457-1578  Wiring Harness  Harness Assembly - Gen V (EMCP4.2 - AssetIQTM
2L-8076  Ring Terminal  Terminal - Insulated (ring-Crimp Type) 
7W-0482  Fuse  Fuse, 2 A 
3N-5977  Fuse Block  Block - Fuse 
033-4814  Screw   
8T-0328  Hard Washer  Washer - Hard 
9S-5937  Locknut   
460  8C-8792  Electrical Wire  Wire - Bulk (Electrical) 
2L-8079  Ring Terminal  Terminal - Insulated (ring-Crimp Type) 
4L-6454  Bolt   
8T-4121  Hard Washer  Washer - Hard 
3K-6060  Locknut   

Generator Current Harness



Illustration 7g03837169
Generator current harness wiring diagram

Due to the variations in length requirements, the generator current harness must be assembled at installation, as shown in Illustration 7, using the components that have been provided in the kit, as listed in Table 5. This harness will connect to connector "C11" as shown in the main wiring harness. To build this harness, there are three current transformers needed that are sized to the generator output current. Refer to Illustration 7. Secondary current can be 0-1 A or 0-5 A. Cat ET must be used to configure the AssetIQTM ECM for either 0 to 1 or 0 to 5 A to match the current transformer secondary current rating. This harness will connect to connector "C11" as shown in the Illustration 5.

Table 5
481-2122 Field Installation Group (Gen Current Harness) 
Qty  Part Number  Part Name  Description 
155-2272  Connector Plug Assembly  Plug As - Connector (4) 
9X-3402  Connector Socket   
155-2262  Plug Lock Wedge  Wedge - Plug Lock (4) 
1220 cm (480.3 inch)  206-3985  Wire  Wire - Bulk (Electrical) 
2L-8076  Ring Terminal  Terminal - Insulated (Ring - Crimp Type) 

Table 6
Generator Current Transformers Available from Caterpillar 
Part Number  Part Name  Description 
117-9721  Current Transformer Assembly  200:5 A, 600 V, stud terminals 
117-9722  Current Transformer Assembly  300:5 A, 600 V, stud terminals 
117-9723  Current Transformer Assembly  400:5 A, 600 V, stud terminals 
122-6585  Current Transformer Assembly  1000:5 A, 600 V, stud terminals 
122-6586  Current Transformer Assembly  1200:5 A, 600 V, stud terminals 
122-6587  Current Transformer Assembly  1500:5 A, 600 V, stud terminals 
357-1219  Transformer  1500:5 A, 600 V, stud terminals 
122-6588  Current Transformer Assembly  2000:5 A, 600 V, stud terminals 
122-6589  Current Transformer Assembly  2500:5 A, 600 V, stud terminals 
122-6590  Current Transformer Assembly  3000:5 A, 600 V, stud terminals 
356-1431  Transformer  3000:5 A, 600 V, stud terminals 
128-0115  Current Transformer Assembly  3500:5 A, 600 V, stud terminals 
122-6591  Current Transformer Assembly  4000:5 A, 600 V, stud terminals 

Engine Speed Sensor Harness



Illustration 8g03837353
Engine speed sensor harness wiring diagram

Due to the variations in length requirements, the engine speed sensor harness must be assembled, as shown in Illustration 8, using the components that have been provided in the kit, as listed in Table 7. This harness will connect to connector "C3" as shown in the Illustration 8, and Illustration 4.

Table 7
481-2125 Field Installation Group (Speed Sensor) 
Qty  Part Number  Part Name  Description 
318-1181  Speed Sensor Group  Sensor Group - Speed (Magnetic) (Low Output) 
155-2269  Connector Plug Assembly  Plug Assembly - Connector (2) 
9X-3402  Connector Socket  Socket - Connector 
155-2261  Plug Lock Wedge  Wedge - Plug Lock (2) 
3E-3376  Connector Receptacle Assembly  Receptacle Assembly - Connector (4) 
9X-3401  Connector Pin  Pin - Connector 
8T-8737  Seal Plug  Plug - Seal 
3E-3377  Receptacle Lock Wedge  Wedge - Receptacle Lock (4) 

Engine Oil Pressure Sensor Harness



Illustration 9g03837624
Oil pressure sensor harness wiring diagram

Due to the variations in individual installations, the engine oil pressure sensor harness will need to be assembled, as shown in Illustration 9, using the components that have been provided in the kit, as listed in Table 8. This harness will connect to connector "C4" as shown in Illustration 9, and Illustration 4.

Table 8
481-2124 Field Installation Group (Oil Pressure Sensor) 
Qty  Part Number  Part Name  Description 
320-3060  Pressure Sensor Group  Sensor Gp - Pressure (1200 kpa, M12×1.5) 
6V-9028  O-Ring Seal  Seal-O-Ring - STOR (ISO Metric M12) 
281-8804  Connector Plug Assembly  Plug As - Connector (3) (Key 4) 
9X-3402  Connector Socket  Socket - Connector 
3E-3376  Connector Receptacle Assembly  Receptacle As - Connector (4) 
9X-3401  Connector Pin  Pin - Connector 
3E-3377  Receptacle Lock Wedge  Wedge - Receptacle Lock (4) 

Engine Coolant Temperature Sensor Harness



Illustration 10g03837627
Coolant temperature sensor harness wiring diagram

Due to the variations in individual installations, the engine coolant temperature sensor harness will need to be assembled, as shown in Illustration 10, using the components that have been provided in the kit, as listed in Table 9. This harness will connect to connector "C5" as shown in Illustration 10, and Illustration 4.

Table 9
489-3082 Temperature Sensor Group (Coolant) 
Qty  Part Number  Part Name  Description 
106-0735  Temperature Sensor Group  Sensor Group - Temperature (PWM 500 HZ 8V) 
3K-0360  O-Ring Seal  Seal-O-Ring - STOR SAE 9/16-18) 
155-2267  Connector Plug Assembly  Plug Assembly - Connector (3) 
155-2276  Plug Lock Wedge  Wedge - Receptacle Lock (3) 
9X-3402  Connector Socket  Socket - Connector 

Installation of the Sensors



Illustration 11g03823057
Sensor orientation

If the sensor has an opening for the fluid being measured, the opening must face downward after installation such that debris is not able to collect in the sensor opening.

Software Requirements

Flashing the ECM requires the following hardware and software:

  • Caterpillar® Service Tool software installed and licensed on a PC

  • Caterpillar Communication Adapter

Use the following files when flashing or configuring:

  • ECM Flash File: 3555019.fls

  • Configuration File: Midrange_2014-11-26_07.25.00.XML

Note: Configuration file is most recent .xml file and is subject to change.

Configuration of the Installed System

The ECM has been preconfigured for the coolant temperature and oil pressure parameters. Configuration of the system requires that the number of teeth in the engine should be configured under "Flywheel Teeth", using Cat ET.



Illustration 12g03837629
Engine speed monitor ECM mounting hardware

If the number of flywheel teeth is unknown or if an accessory drive gear is being sensed, the engine RPM must be determined either from the dashboard tachometer or a handheld tachometer. The number of flywheel teeth can be calculated as follows:



Illustration 13g03823063
Flywheel teeth computation

Validation of the Installed System

Electrical Validation

Power OFF Tests

This check will be performed on the AssetIQTM generator system to validate that the following wires have been terminated correctly. For this check, verify that the 70-pin harness is disconnected from the ECM. The 70-pin harness includes the extension harnesses and sensors. Using a digital volt meter set to measure ohms, perform the following resistance checks:

Testing the Engine Magnetic Pickup:

  • Connect the positive lead to "C1" pin-66.

  • Connect the negative lead to "C1" pin-67.

  • The resistance should read 175 ± 20 ohms.

Testing the Data Link Connection:

  • Connect the positive lead to "C8" pin-G.

  • Connect the negative lead to "C8" pin-F.

  • The resistance should read 60 ohms.

Testing the Current Sensing Harness:

  • Current sensing harness must be connected for this test "C11 to C13".

Table 10
Positive lead  Negative lead  Resistance reading 
C1-39  C1-31  10 ohm or less 
C1-39  C1-47  10 ohm or less 
C1-39  C1-57  10 ohm or less 

Testing the Voltage Sensing Harness:

  • Remove Fuses 1, 2, and 3.

Table 11
Positive lead  Negative lead  Resistance reading 
C1-7  C1-13  Infinite 
C1-7  C1-11  Infinite 
C1-7  C1-9  Infinite 
Neutral Tab  1 ohm or less 

  • When finished with each individual check, reinstall the three fuse resistance from C1-7 to C1-9, 11, 13 should be less than 10 ohms.

Power ON Tests

Before connecting the battery, perform the following checks on the oil pressure sensor and the coolant temperature sensor. Using a digital volt meter set to measure DC V, perform the following checks:

Battery Check (Refer to Illustration 4):

  • Connect the positive lead to "C23" pin-1.

  • Connect the negative lead to "C23" pin-2.

  • The voltage should read 24 V.

  • Connect Battery power by connecting "C23" to "C2".

Oil Pressure Harness (Refer to Illustration 9):

  • Connect the positive lead to "C17" pin-1.

  • Connect the negative lead to "C17" pin-2.

  • The voltage should read 5 V.

  • Connect "C17" to the oil pressure sensor.

Coolant Temperature Harness (Refer to Illustration 10):

  • Connect the positive lead to "C30" pin-A.

  • Connect the negative lead to "C30" pin-B.

  • The voltage should read 5 V.

  • Connect "C30" to the coolant temperature sensor.

Functional Validation

  1. Remove the "Do Not Operate" warning label and lock from the ignition.

  2. Connect the AssetIQTM system to Battery(+) and Battery(-). Connect a Communications Adapter to the 9-pin service port on the AssetIQTM harness.

  3. Connect to the AssetIQTM system in Cat ET and start the engine to which the sensors are connected.

  4. With the Engine running, verify that the following parameters are being reported.

    • Oil Pressure

    • Coolant Temp

    • Battery Voltage

    • Engine Speed

    • Diagnostic Clock

  5. Let the engine run for 5 minutes,

    • Verify that the coolant temperature has increased after running.

    • Verify that the oil pressure is within specification at idle.

    • Increase the throttle on the engine and verify that engine speed increases.

  6. If any of the parameters report as unavailable, check that all electrical connections between the sensor and the harness.

  7. If a parameter reports a "Voltage Below Normal" diagnostic, check the wires for a short circuit.

  8. If a parameter reports a "Voltage Above Normal" diagnostic, check the wires for an open circuit.

Caterpillar Information System:

C9.3 Marine Engine Engine Oil Pan - Remove and Install - Left-Hand Service Oil
3516B Generator Set Engines with Dynamic Gas Blending Exhaust System Contains Oil
C9.3 Marine Engine Engine Oil Pan - Remove and Install - Combined Circuit Keel Cooling
C280-08 Tier 4 Engine Exhaust Manifold Shield - Remove and Install
C9.3 Marine Engine Engine Oil Pan - Remove and Install - Right-Hand Service
3500 Generator Sets with Dynamic Gas Blending Generator Bearing - Replace
2015/08/14 A New Control Valve Assembly for Fuel Is Used on Certain 3500 Marine Engines {1261}
3500 Generator Sets with Dynamic Gas Blending Generator Bearing - Inspect
2015/07/07 An Improved Housing for the Throttle Inlet Is Used on Certain G3500 Engines {1071}
12M Motor Grader Wheel Lean Bearings - Lubricate
3500B High Displacement Locomotive Engines Fuel Injector Mechanism
C9.3 Marine Engine Cylinder Head - Remove and Install
3500 Industrial Engines Fuel Injector Mechanism
3512C and 3516C Industrial Engines Engine Oil Filter
C280 Marine Engines Circuit Breaker - Test
3512C and 3516C Industrial Engines Air Lines
G3606 and G3608 Engines Aftercooler - Disassemble
C9.3 Marine Engine Coolant Temperature Sensor - Remove and Install
3516E Generator Set Engine Sensor Calibration Required - Test
C9.3 Marine Engine Engine Oil Pressure Sensor - Remove and Install
C280-08 Tier 4 Engine Exhaust Manifold - Remove and Install
C280-08 Tier 4 Engine Aftercooler - Remove and Install
C280-08 Tier 4 Engine Turbocharger - Remove and Install
C280-08 Tier 4 Engine Air Inlet Shutoff - Remove and Install
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.