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Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This Special Instruction contains information for installing the Cat Data Link (CDL) to J1939 Converter on all Caterpillar Generator Sets with the EMCP 4.2 Upgrade. The CDL to J1939 Converter kit will enable older Engine Electronic Control Module (ECM) with CDL protocol only to communicate with the EMCP4.2.
Safety Section
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. The installer must be alert to potential hazards and have the necessary training, skills, and tools needed to perform these functions properly. Wear safety equipment, such as eye protection and foot protection, and other protection as is appropriate to the work site.
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 product will not damage 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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Accidental engine starting can cause injury or death to personnel. To prevent accidental engine starting, turn the ignition switch to the OFF position, place a do not operate tag at the ignition switch location and disconnect and tape the electrical connection to the stop solenoid that is located on the fuel injection pump. |
Applicability
The CDL to J1939 Converter is offered as an aftermarket attachment for use on Caterpillar Generator Sets with the EMCP4.2 Upgrade.
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 control and connection of a Cat® Electronic Technician (Cat ET) communications adapter will add to the current draw.
Features
A new kit will come with the ECM with translation software, harness and mounting hardware.
CDL to J1939 Converter Kit Supplied Parts for Installation
The required parts for CDL to J1939 Converter Kit are listed in Table 1.
| Contents of the 533-0545 INSTL GP-FIELD | |
|---|---|
| Qty | Part |
| 1 | 532-7097 Harness As |
| 4 | 3T-0852 Locknut |
| 4 | 6I-1418 Spacer |
| 4 | 6V-5221 Bolt |
| 8 | 8T-9655 Isolation Mount |
| 1 | 377-4710 Electronic Control Module |
| 1 | 544-2978 Machine Software Gp |
Additional Parts Needed for Installation
This kit is required to protect the ECM from voltage spikes that could cause damage.
Electronic Control Module Mounting Bracket
Given the wide range of machines to which the CDL to J1939 Converter system can be applied, a standardized mounting method is not possible. Some of the considerations to be made when selecting an ECM mounting location include:
- Access to a fused source of +24V power.
- Access to "Keyswitch" as supplied by the ignition system.
- Access to battery ground.
- Access to the main data link(s) on the machine.
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.
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| Illustration 1 | g06202084 |
Installation of the ECM
The ECM will be located on a field fabricated bracket in a location of the installer’s choice. When selecting a mounting location, consider accessibility of Engine ECM as well as the EMCP4.2. Electrical connections should avoid sharp bends at connectors, sharp edges, and chafing surfaces. Harnesses should be supported at no less than
The required hardware in the kit for mounting the ECM to the mounting plate are listed in Table 1.
| Qty | Part |
|---|---|
| 4 | 6V-5221 Bolt |
| 4 | 9N-0869 Hard Washer |
| 4 | 3T-0852 Locknut |
| 4 | 6I-1418 Spacer |
| 8 | 8T-9655 Isolation Mount |
The ECM will need to be secured to a field fabricated bracket. Use the following ECM requirements to fabricate a bracket for the ECM in a location that meets the requirements.
- Access to a fused source of +24V power.
- Access to Key switched power as supplied by the ignition system.
- Access to battery ground.
- Access to the main data link or links on the machine.
- There are four mounting points on the ECM, one at each corner. Drill a hole to accommodate a size M8 bolt that corresponds to each mounting point.
- Use one 6V-5221 Bolt, two 9N-0869 Hard Washers, one 8T-9658 Spacer, two 8T-9655 Isolation Mounts, and one 3T-0852 Locknut at each mounting location of the ECM.
- One corner of the ECM includes a ground strap. If the ECM must be mounted to a non-conductive portion of the machine, use a ring lug and wire to connect the ground strap to the nearest ground point on the machine chassis. The conductive flat surface of the lug must be directly connected to a conductive surface that is bonded to the machine chassis.
Software Installation
- Using a Communications Adapter, connect to the Service port, CDL-J1939 on 532-7097 Harness AS. Turn on power without starting the engine.
- Using Caterpillars Electronic Technician, connect to the CDL-J1939 ECM. When connecting, the ECM will report that it needs to have its software installed.
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Illustration 2 g06293555 - Proceed to the WinFlash Screen as show above.
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Illustration 3 g06293563 (1) File Selection - Select the File Selection icon and navigate to where you have the software stored.
- Select the software file and select Begin Flash at the bottom of the screen and the software will begin to be flashed onto the ECM.
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Illustration 5 g06293622 (1) CatET - Select the Cat ET button in the popup window to take you back to the Cat ET ECM Summary screen.
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Illustration 4 g06293618 Show/hide table
Illustration 6 g06293624 - Select the software file and select Begin Flash at the bottom of the screen and the software will begin to be flashed onto the ECM.
- Once you confirm that the software has been successfully installed on the ECM, return to Step 7 of the Installation of the Electrical Harness section of this special instruction.
Installation of the Electrical Harnesses
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.
- Install the 532-7097 Harness As on the ECM.
- Connect 464-7820 Electrical Installation Gp E-C1 to connector A-C2 of the 532-7097 Harness As CDL to J1939 Harness. Route the flying leads from the VLPM harness to the nearest location to splice into system Battery (+), Ground, and key switch.
Note: For systems that do not have a key switch signal, this input should be tied to positive battery voltage. Once spliced in, give each wire a pull test to ensure a good crimp before proceeding.
- Route the shielded J1939 line into the dog house and up into the EMCP 4.2 through one of the conduit ports in the bottom of the EMCP 4.2. Once in the cabinet, strip back
51 mm (2.0 inch) of the insulation and shielding. - Install 9X-3401 Connector Pin on the CAN wires. As a precaution, give each pin a pull to ensure that a good crimp was made to retain the pins.
- Insert the CAN HI (+) wire into position "A" of 133-0973 Receptacle As and CAN LO (-) into position "B".
- Install 133-0975 Receptacle Lock Wedge into the Receptacle As. As a precaution, give each wire a pull to ensure that each pin is seated properly in the connector.
- Remove 134-2540 Connection Resistor As terminating resistor on E-C19 and install the new connector onto the EMCP 4.2 Harness As.
- Route the CDL lines (GN/BN twisted pair) to the Engine ECM.
- Install 9X-3402 Connector Socket onto each wire. As a precaution, give each socket a pull to ensure that a good crimp was made to retain the sockets.
- Remove the connector from the Engine ECM and remove the cover from the connector.
- Insert CDL(+) (GN) into the CDL(+) socket on the ECM connector. Insert CDL(-) (BR) into the CDL(-) socket on the ECM connector.
- Once inserted into the connector, give each lead a pull to ensurethey are properly seated in the connector. Reassemble the cover onto the connector and reinsert the connector into the ECM.
Electrical Validation of the Installed System
Conditions to Perform the Validation Procedure
Note: Before beginning the validation procedure, make sure that all the following conditions, as listed below:
Remove the A-C1 connector from the ECM. Validate that:
- A-C2 is connected to E-C1 of VLPM Harness
- J1939 lines are connected to E-C19 of EMCP4.2
- CDL lines are connected to the Engine ECM
Power Off Test
Conditions:
- Ignition switch in OFF position
- Using a Digital Multi-Meter set to measure Ohms (Ω), connect the positive (+) lead to A-C1-64 and connect the negative (-) lead to A-C1-65. There should be a nominal resistance reading of 60 Ohms (Ω).
Conditions:
- Ignition switch in Off position
- Using a Digital Multi-Meter set to measure Ohms (Ω), connect the positive (+) lead to A-C1-57 and connect the negative (-) lead to A-C1-70. There should be a nominal resistance reading of 5k Ohms (Ω).
Power On Tests
- Connect a digital volt meter negative lead to the machine chassis.
- With the power OFF, connect a digital volt meter positive lead to A-C1-1. The resistance should be less than 3 ohms and no voltage present.
- With the power ON, connect a digital volt meter positive lead to A-C1-1. The expected result is battery voltage.
- With the power ON and the key switch OFF, connect a digital volt meter positive lead to A-C1-3.The expected result is close to zero (0) volts unless the system does not have a key switch. For systems with no key switch, the expected result is battery voltage.
- Turn Keyswitch to the OFF position.
- Connect Caterpillar Communications Adapter to A-C5. Set protocol option to J1939.
- Turn Keyswitch to the ON position.
- Using Cat ET, verify that one ECM and the EMCP is detected.
- Check to make sure that there are no errors being reported.
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| Illustration 7 | g06202163 |
Above is an example screenshot you should see when connected to the CDL to J1939 Converter.