17 december 2008 special instruction · 17 december 2008 special instruction i03297929 installation...

REHS2362-0217 December 2008

Special Instructioni03297929

Installation Guide for thePL1000E CommunicationsECMSMCS Code: 7610

Electric Power GenerationAll

Engine Industrial, Marine, and GeneratorSet that Use Flash ProgrammingAll

Table of ContentsIntroduction ........................................................... 1Required Tools ...................................................... 1Parts List ............................................................... 2Additional Parts that may be needed .................... 2Considerations for Mounting the ECM .................. 3Installation of the ECM Module ............................ 3Desk Mounting Method ..................................... 3Shock Mount Method ........................................ 3Preferred Shock Mounting Method using weldbosses or weld studs ................................... 4Shock Mounting that Uses Bolts and ThreadedHoles for Mounting ....................................... 5Shock Mount the ECM with the Use of Bolts andThrough Holes ............................................. 5

Wiring Requirements and Installation ................... 6ECM Connector and Wiring HarnessConnections .................................................... 8Requirements for the System Power Wiring .... 10Requirements for Wiring Cat DatalinkCommunications .............................................. 12J1939 Communications Wiring Requirements .. 15RS-485 and RS-422 Harness Requirements .... 17RS-232 Wiring Requirements ........................... 19Wiring Requirements for Ethernet ..................... 20Building the Custom Harness Assembly ........... 21Connecting the Harness Assembly to the PL1000ECommunication ECM ...................................... 21Connecting the Custom Harness to theSystem ............................................................ 21ECM Template ................................................... 21

IntroductionThis Special Instruction provides information forthe installation of the 256-7512 CommunicationElectronic Control Module (PL1000E). Refer toSystems Operation, RENR8091 for more informationabout the 256-7512 PL1000E Communication ECM.

Do not perform any procedure that is outlined in thisspecial instruction, or order any parts until the entirespecial instruction has been read and understood.

Refer to Special Instruction, REHS4498 forthe required procedures to configuring and toprogramming the PL1000E.

Required ToolsThe following tools will be required to install the256-7512 PL1000E Communication ECM. The listbelow contains the recommended Caterpillar servicetools.

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Table 1

PartNumber

Description

Laptop Computer

JERD2124 Caterpillar Electronic Technician (Cat ET)Version 2007B or later

JERD2129 Date Subscription for all engines andmachines

EERP1000 Caterpillar Tool Kit Version 2007B or later

171-4400 Communication Adapter Gp (Cat ET TOECM INTERFACE) (optional)(1)

9U-7330 Digital Multimeter

7X-1710 Multimeter Probe

1U-5804 Crimp Tool (12-AWG TO 18-AWG)

175-3700 Connector Repair Kit (DT)

Two short jumper wires(2)

Long extension wire(3)

4 mm (5/32 inch) Allen wrench(1) The 7X-1700 Communication Adapter Gp or the embeddedcommunication adapter of the ECM may also be used.

(2) Two short jumper wires are needed to check the continuity ofsome wiring harness circuits by shorting two adjacent terminalstogether in a connector.

(3) A long extension wire may also be needed to check thecontinuity of some wiring harness circuits.

Parts ListTable 2

Required Parts

Quantity Part Number Description

10 7K-1181 Cable Strap

4 8C-5608 Spacer

4 8C-8451 Bolt

8 9X-6165 Washer

8 9X-9896 Isolation Mount

4 117-1660 RubberBumper(1)

4 129-3178 Locknut

1 256-7512 PL1000ECommunicationECM withFlashedapplicationsoftware

1 276-0785 HarnessAssembly

1 228-6559 HarnessAssembly

(1) The rubber bumper has an adhesive back. The rubber bumperis applied to the bottom of the ECM when shock mounting isnot required. The rubber bumper is for use when mounting theECM on a table or desk only.

Additional Parts that may beneededFor most applications, the 276-0785 HarnessAssembly will require additional wiring. Table 3 listsoptional components that may be needed in order tocomplete the wiring for the intended application.

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Table 3

Additional Wiring Components


1-70 9X-3402 Connector Socket (16AWG to 18 AWG)

1-70 126-1768 Connector Socket (14AWG)

1-3 163-5620 Plug Assembly (DB-9Style)

1-3 163-6484 Receptacle Assembly(DB-9 Style)



1-2 163-5619 Receptacle Assembly(DB-25 Style)

1-4 5N-4988 Isolation Diode (Single)

1 7C-2668 Isolation Diode (4 Pack)

1-2 134-2540 Receptacle Assembly(J1939 TerminatingResistor)

199-9785 Wire Assembly (Splice)

207-3814 Wire Assembly (Splice)

115-8109 Wire Splice (SingleSealed)

Some installations may require additional mountinghardware to secure the ECM to a mounting surface.The methods for installation are detailed in the“Installation of the ECM Module” section. Table 4 liststhe optional components for mounting the ECM.

Table 4

Additional Components for Mounting the ECM


4 Various M6 X 1 boltor weld stud(length variesdependingon mountingmethod)

4 Various M6 X 1 weldboss, nut, orsimilar fastener

Considerations for Mounting theECMIdentify a mounting location for the ECM. Measurethe location in order to ensure correct spacing for theECM “footprint” and the harness routing.

Keep in mind the mounting location of the PL1000E.

The PL1000E 256-7512 Communication ElectronicControl Module v4, must be mounted in a locationthat will not expose the PL1000E to temperaturesabove 85 °C (185 °F). If the temperature at thelocation is unknown, mount the PL1000E in a locationthat can be properly ventilated.

The PL1000E 256-7512 Communication ElectronicControl Module v3, must be mounted in a locationthat will not expose the PL1000E to temperaturesabove 70 °C (158 °F). If the temperature at thelocation is unknown, mount the PL1000E in a locationthat can be properly ventilated.

Determine the appropriate mounting method for eachspecific application. The mounting can be a shockmount or a desk mount.

NOTICEFor mounting applications where the ECM maybe subjected to shock or vibration, use the shockmounting method. Use the desk mounting methodfor mounting applications where the ECM will not beexposed to shock or vibration.

When mounting the ECM, orient the ECM so that theECM connector is not subjected to high pressurespray or underwater submersion. Exposure tohigh pressure spray or underwater submersionmay compromise the connector seal and lead toconnection failure.

When mounting the ECM, orient the ECM so that theECM is not used as a “boot step” or a fulcrum point.The ECM is made of a high strength cast aluminum,but can still be damaged.

Installation of the ECM Module

Desk Mounting Method

1. When mounting the ECM on a stable surfacesuch as a table or desk, assemble four of the117-1660 Rubber Feet to the bottom side of theECM. One rubber foot must be installed at eachcorner of the ECM. The bottom side of the ECM isthe side opposite of the ECM connector.

2. Place the ECM in the desired location on a flatlevel surface.

Shock Mount Method

There are several different methods in order to shockmount the ECM. Select a method that is appropriatefor the intended application and environment.

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Preferred Shock Mounting Method using weldbosses or weld studs

The preferred method in order to shock mount theECM requires the use of weld bosses or weld studs.Refer to Illustrations 1 and 2.

1. Locate the ECM template. Place the templatein the desired location in order to mount theECM. The ECM template is located in the “ECMTemplate” section that is located at the end of thispublication. The ECM template is Illustration 18.

2. Mark the location for each of the mounting holes.

3. Remove the template.

4. Weld the bosses or studs at the marked locations.

5. Mount the ECM as shown in Illustration 1 orIllustration 2.

6. Tighten each of the fasteners to 12 N·m (9 lb ft).

g01111540Illustration 1Example of the Shock Mount that Uses Bolts and Weld Bosses

(1) M6 x 1, 43 mm (1.75 inch) bolt(2) 9X-6165 Washer(3) 9X-9896 Mount(4) 8C-5608 Spacer(5) 256-7512 PL1000E Communication ECM(6) M6 x 1 Weld Boss, Weld Nut, or Similar Fastener(7) Mounting Plate

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g01111773Illustration 2Example of the Shock Mount that Uses Weld Studs

(1) 256-7512 PL1000E Communication ECM(2) M6 x 1 Locknut(3) 9X-6165 Washer(4) 9X-9896 Mount(5) M6 x 1, 43 mm (1.75 inch) weld stud(6) 8C-5608 Spacer(7) Mounting Plate

Shock Mounting that Uses Bolts and ThreadedHoles for Mounting

Shock mounting an ECM that use threaded holes willrequire the use of drilled and tapped holes to mountthe ECM. Refer to Illustration 3.

1. Locate the template for the ECM. Place thetemplate in the desired mounting location. Thetemplate is located in the “ECM Template” sectionthat is located at the end of this publication. Thetemplate is Illustration 18.



4. Drill a 4 mm (11/64 inch) hole at each markedlocation.

5. Tap each hole with a M6 x 1 tap in order to providethe threaded holes for the M6 x 1 bolts.

6. Mount the ECM as shown in Illustration 3.

7. Tighten the bolts to 12 N·m (9 lb ft).

g01111821Illustration 3Example of the Shock Mount that Uses Threaded Mounting Holes(1) M6 x 1, 43 mm (1.75 inch) bolt(2) 9X-6165 Washer(3) 9X-9896 Mount(4) 8C-5608 Spacer(5) 256-7512 PL1000E Communication ECM(6) Mounting Plate

Shock Mount the ECM with the Use of Bolts andThrough Holes

Shock mounting the ECM by use of through holeswill require drilling four clearance holes. Refer toIllustration 4.

1. Locate the template for the ECM. Place thetemplate in the desired mounting location. Thetemplate is located in the “ECM Template” sectionthat is located at the end of this publication. Thetemplate is Illustration 18.


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4. Drill a 6.35 mm (0.25 inch) hole at each markedlocation.

5. Mount the ECM as shown in Illustration 4.

6. Tighten the bolts to 12 N·m (9 lb ft).

g01111894Illustration 4Example of a Shock Mount with the Use of Through Holes

(1) 256-7512 PL1000E Communication ECM(2) M6 x 1 Locknut(3) 9X-6165 Washer(4) 8C-5608 Spacer(5) 8C-5607 Mount(6) Mounting plate(7) M6 x 1, Bolt minus the Length = 43 mm plus the Mounting

Plate Thickness

Wiring Requirements andInstallationThe purpose for the 276-0785 Harness Assembly isto provide basic power and communications capabilitywith the 256-7512 PL1000E Communication ECM.The harness connectors are shown in Table 5.

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Table 5

Connector Part Number Description

ECM 160-7690 70 pin AMP rectangular plug. Provides the connection to the PL1000ECommunication ECM.

Power 3E-3376 4 pin Duetsch (DT) style rectangular receptacle. The connector provides ready accessto the battery and key switch connections on the PL1000E Communication ECM.

Service Tool 8T-8735

9 pin Duetsch HD-10 style round plug. The connector is the standard service toolconnector found on most Caterpillar machine and engine connections that are for usewith the 171-4400 Communications Adapter II or similar communications device.The communications device is connected to a PC serial port or parallel port allowingthe PC to communicate with the Cat Datalink network or the J1939 No. 1 networkusing standard Caterpillar tools such as Cat ET.

EmbeddedComm Adapter 257-2719

9 pin AMP DB plug. The connector provides a similar function as the ServiceTool connector expect that the connector can plug directly into a PC rather thanmust go through a 171-4400 Communications Adapter II or similar device. Referto the section “Embedded Comm Adapter Connection Group” in Table 6 for moreinformation.

NOTICEThe technician must provide additional wiring in orderto complete the installation of the ECM into a customcommunication system. The 276-0785 HarnessAssembly electrical diagram is shown in Illustration 5.The wiring of individual power and communicationscircuits is detailed in subsequent sections.

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ECM Connector and Wiring HarnessConnections

g01416941Illustration 5

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Note: The 258-4548 Electronic Control Module isan ECM with out any software installed. After thesoftware is installed that is used for the PL1000E, thepart number becomes 256-7512 CommunicationElectronic Control Module (v3). The 256-7512Communication Electronic Control Module (v3) cannot be configured for RS-485 2 wire.

Note: The 285-1138 Electronic Control Module,Multi node v4, is an ECM with out any softwareinstalled. After the software is installed, that isused for the PL1000E, the part number becomes256-7512 Communication Electronic ControlModule (v4). The 256-7512 CommunicationElectronic Control Module (v4) can be configured forRS-485 2 wire or RS-485 4 wire.

Refer to Illustration 5 for possible connectionsthat can be made to the 256-7512 PL1000ECommunication ECM for specific applications. Theconnection groups that are shown in Illustration 5 aredescribed in Table 6. Use only the connection groupsthat are necessary for the specific application.

Note: Most of the connection groups requirespecial configurations of the 256-7512 PL1000ECommunication ECM. In order to make the changes,use Cat ET 2007B or higher or Cat Toolkit 2007Bor higher as shown in Table 1. Refer to SystemOperation, RENR8091 for specific information aboutthese special configurations.

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Table 6

Applications for the Connection Groups

System Power Connection Group

The system power connection group provides a standardelectronic control power connection between system powerand the ECM. Refer to the section “System Power WiringRequirements” for specific wiring requirements.

Cat Datalink (CDL) Connection Group

The Cat Datalink group provides a standard Cat Datalinkconnection. This connection must be used whenusing the PL1000E Communication ECM's EmbeddedCommunications Adapter (ECA) feature to servicea CDL compatible device using standard Caterpillarservice tools, such as Cat ET. Refer to the “Cat DatalinkCommunications Wiring Requirements” section for specificwiring requirements.

J1939 Network Connection Group

The J1939 network connection group provides a standard“CAN” bus connection operating at a 250,000 baud rate.The J1939 network connection group must be connectedin order to implement the PL1000E Communication ECM'sJ1939 to Modbus feature. Additionally, the J1939 networkconnection group may also be connected in order to facilitateconnections to the J1939 compatible devices using thePL1000E Communication ECM's embedded communicationsadapter feature for standard Caterpillar service tools, suchas Cat ET. Refer to “SAE J1939-11”, “SAE J1939-15”, andthe “J1939 Communications Wiring Requirements” sectionfor specific wiring requirements.

RS-485 Network Connection Group

The RS-485 Connection Group is capable of providinga RS-485 (4 wire or 2 wire or RS-422 connection thatcan be used for Modbus communications. The PL1000ECommunication ECM must be configured for the appropriateprotocol and baud rate. Refer to the System Operation Testand Adjust, RENR8091, “ECM - Configure” for availableconfiguration values.

RS-232 Serial Connection Group 1&

RS-232 Serial Connection Group 2

The RS-232 serial connection groups provide a standardRS-232 serial interface programmable to operate in the rangeof 4800 to 115200 baud rate. The serial connection groupscorrespond to the PL1000E Communication ECM serialports 1 and 2. Refer to the “RS-232 Communications WiringRequirements” section for specific wiring requirements.

Embedded Communications Adapter Connection Group

The embedded communications adapter connection groupprovides a standard RS-232 serial interface. The interfacecan operate within a baud rate range from 9600 to 115000.The embedded communications adapter connection groupmust be connected in order to make use of the PL1000ECommunication ECM's embedded communications adapterfeature. The embedded communications adapter featureallows standard Caterpillar service tools, such as Cat ET tointerface with a CDL device or a J1939 device.

Ethernet Connection Group

The Ethernet connection group provides an interface for usewith the Modbus TCP, embedded web pages, and the FTP.This connection group may be installed for either a networkconnection or a cross over direct connection.

Requirements for the System PowerWiring

The power connector in the 276-0785 HarnessAssembly provides a direct connection to theswitched power inputs and the power inputs that arenot switched.

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NOTICEThe 276-0785 Harness Assembly contains218-4935 Arc Suppressors to protect the internalcircuitry of the 256-7512 PL1000E CommunicationECM from high voltage transients. DO NOT removethese transient devices from the 276-0785 HarnessAssembly. DO NOT rewire the system to avoidthe transient devices. If the transient devices areremoved or if the system is rewired in order to avoidthe transient devices, then the warranty for the256-7512 PL1000E Communication ECM will bevoided.

The parameters for the basic power connections areshown in Table 7. Basic electrical connections areshown for single power sources in Illustration 6. Basicelectrical connections are shown for multiple powersources in Illustration 7.

Table 7

Parameters for the Basic Power Connections

ValueParameter

Min Nominal Max

VoltagebetweenBATT+ andBATT-

9 DCV 12 DCV or24 DCV 32 DCV

CurrentDraw (1) 0.5A 5A

(1) Provide fuse protection for the BATT+ and KEYSW to not allowthe current to exceed 5 amps


Example of the Connection for a Single Power Source

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g01145216Illustration 7Example of the Connections for Multiple Power Sources

Additional information for power connections thatmust be considered:

• Minimum 18 AWG wire should be used for theKEYSW, BATT+, and BATT- connections andharnessing.

• The key switch connection “activates” thePL1000E. If a key switch does not exist in theelectrical system, or if it is desired to have thePL1000E powered at all times, then connect theKEYSW connection directly to BATT+.

• The power supply that has the BATT- tied to acommon ground for the system components thatare used for a particular circuit, must also supplythe power for the system components that are tiedto that same circuit. Grounding requirements mayvary from one application to another application.Consult the system schematics and other systemdocumentation for grounding requirements.

• Provide fuse/circuit protection for BATT+ andKEYSW. The fuse protection must not allow thecurrent to exceed 5 amps.

• Provide diode isolation in circuits that have multiplepower sources. The diodes isolate the powersources and allow the PL1000E to remain poweredif at least one power source is operational.

• Use good wire routing practices and wire securingpractices in order to avoid damage to the cable.

• Route the cable in order to avoid inducing electricalnoise into the cable from high power and sourcesof high frequency.

• Install the 8T-8737 Seal Plugs into any unusedsockets at the rear of the connector.

Requirements for Wiring Cat DatalinkCommunications

The Cat Datalink communications connectionprovides a connection between the PL1000E and theCat Datalink network.

The use of “Boost Disabled” or “Boost Enabled” candetermine the physical location for installation of thePL1000E.

The PL1000E can be installed close to the systemwith the use of “Boost Disabled” as long as thetotal network wiring length of 30.5 m (100 ft) is notexceeded.

The PL1000E can be installed at further distancesaway from the system with the use of “Boost Enabled”as long as the total network length of up to 305 m(1000 ft) is not exceeded.

The distances for wiring are dependent on wiregauge, wire resistance, and capacitance of the cable.Refer to Table 8 for specific requirements for wiringand basic parameters. Basic electrical connectionsare shown in Illustration 8 and Illustration 9.

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Note: This note applies to the 256-7512Communication Electronic Control Module v3,258-4548 Electronic Control Module v2, and toearlier versions. If the PL1000E is to be removedfrom system power, the CDL Boost functionmust be disabled in order to prevent internalbackup battery drain. If the PL1000E is removedfrom system power with CDL Boost enabled, thePL1000E internal backup battery will be depletedin as little as 24 hours.

Table 8

Port Characteristics for Cat Datalink

Parameter Value

CDL Boost Disabled CDL Boost Enabled

Maximum Cable Length (1) 30 m (100 ft) 16 AWG wire 300 m (984 ft) 18 AWGwire

Conductor to Conductor .0023 µF .035 µFMaximum Capacitance of the Cable(2)

Conductor to Shield .0044 µF .006 µF

Maximum resistance of the cable for a single conductor (3) 0.43 Ω 6.5 Ω

Maximum number of devices (4) 11 11(1) This length is the total length of all wiring in the Cat Datalink network, including the wiring for the ECM. Refer to Illustration 10 for anexplanation in order to properly calculate cable length.

(2) In order to measure the capacitance of the cable, disconnect all of the devices from the network at the connection for the device. The wiresfor the network must be open between the two conductors. Measure the capacitance between the two wires.

(3) In order to measure the resistance of the cable, disconnect all devices from the network at the connection for the device. The wires for thenetwork must be open between the two conductors. Short the wires together at the PL1000E. Measure the resistance between the twowires at all of the connections of the other devices. For the maximum reading taken, divide the resistance measurement by 2 and thencompare to the value that is shown in this table.

(4) This is the number of devices on the network including the PL1000E Communication ECM.

g01777158Illustration 8Example of Typical Wiring for Cat Datalink Communications that Use the Service Tool Connector

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g01777174Illustration 9Typical Cat Datalink Wired to a 276-0785 Harness Assembly.


Additional Cat Datalink connection information toconsider:

• Connecting to the Cat Datalink network isNOT necessary for operation of the PL1000ECommunication ECM.

• Connecting multiple Cat Datalink networkstogether, without properly configuring theECM's that are on the networks, may causecommunications conflicts among the ECM's andmay cause possible shutdown of the engines orother devices controlled by the ECM's.

• If connecting to a Cat Datalink network, thenconnect to only one network .

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• 16 AWG or 18 AWG common harness wire shouldbe used for wiring the Cat Datalink network as atwisted pair with 1/3 to 1 full twist per inch.

• Use good wire routing and wire securing practicesin order to avoid damage to the cable.

• Run cable away from high power and sources ofhigh frequency in order to avoid inducing electricalnoise into the wiring.

• Each ECM that is installed on the Cat Datalinknetwork must have power system connections thatshare a common ground (BATT-).

• Install the 8T-8737 Seal Plugs into any unusedsockets at the rear of the connector.

J1939 Communications WiringRequirements

The J1939 communications connection provides aconnection between the PL1000E CommunicationECM and the J1939 network. The J1939 networkcontains a bus along with wiring in order to connectthe nodes to the bus. The bus is terminated on eachend in order to complete the network. Table 9 showsthe parameters for the J1939 network and Illustration11 shows a typical J1939 network layout. Illustration12 and Illustration 13 show electrical connectionmethods for J1939.

Table 9

J1939 Port Characteristics

ValueParameter Shielded (SAE

J1939-11)Unshielded

(SAE J1939-15)

Maximum Nodes(n) 30 10

Maximum Lengthof the Bus (1) (L) 40 m (132 ft)

Maximum Lengthof Stub Wire(2) (S) 1 m (3.3 ft) 3 m (9.8 ft)

Node Distance(d) 0.1 m (0.3 ft) to 40 m (131 ft)

Minimumdistance toterminatingresistor (d0)

0.0 m

TerminatingResistors (RT) 120 Ω, 0.5 Watt

(1) Do not include cable stubs in the calculations.(2) Subtract 0.33 meters if the cable stub is for a service portconnector.

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g01157211Illustration 11Typical J1939 Communications Network Layout

g01157214Illustration 12J1939 Communications Wiring that Uses Service Tool Connector

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g01157218Illustration 13J1939 Communications Wiring - Alternate Routing of 276-0785 Harness Assembly

Additional J1939 connection information to consider:

• A terminating resistor must be connected to bothends of the J1939 communications bus for properoperation of the network.

• 16 AWG or 18 AWG common harness wire shouldbe used for wiring the J1939 network as a twistedpair with 1 full twist per inch.


• Run cable away from high power and sources ofhigh frequency in order to avoid inducing electricalnoise into the wiring.

• Each device that is installed on the J1939 networkmust have power system electrical connectionsthat share a common ground (BATT-).

• Install sealing plugs (8T-8737) into any unusedsockets at the rear of the connector.

RS-485 and RS-422 HarnessRequirements

The RS485/422 connection that is on the PL1000Eallows for the communication of the Modbus protocol.The basic parameters are shown in Table 10. Basicelectrical connections are shown in Illustrations 14and 15.

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Table 10

RS-485 Port Characteristics

Parameter Value

Maximum Cable Length 305 m (1000 ft)

Maximum Capacitance of the Cable from one Conductor toanother Conductor(1) .022 µF

Maximum Resistance of the Cable for a single Conductor(2)(3) 39 Ω(1) In order to measure the capacitance of the cable, disconnect all of the devices from the network at each device. The wires for the networkmust be open between the two conductors. Measure the capacitance between the two wires.

(2) In order to measure resistance of the cable, disconnect all devices from the network at each device. The wires for the network must beopen between the two conductors. Short the wires together at the PL1000E Communication ECM. Measure the resistance between thetwo wires at all of the other connections for each device. For the maximum reading taken, divide the resistance measurement by 2.Compare the measured value to the value that is shown in this table.

(3) 256-7512 v3 and earlier hardware requires a 120 ohm impedance matching resistors at each end.



Additional information for the RS-485 connection thatmust be considered:

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The PL1000E part number256-7512 (v4) andbeyond support RS-485 2 wire. Previous versionsdo not support Rashly 2 wire.

• 16 AUG. or 18 AUG. common harness wire shouldbe used for wiring the Rashly network.


• Route the cable away from high power and sourcesof high frequency in order to avoid inducingelectrical noise into the wiring.

• Each device that is installed on the Rashly networkmust have power system connections that share acommon ground (BATT-).


RS-232 Wiring Requirements

The RS-232 communications connection providesa connection between the PL1000E and RS-232devices. The connection conforms to EIA RS-232standards. The connection will work with anyRS-232 devices that also conform to the EIA RS-232standards. Table 11 shows the parameters forconnections for a RS-232 device. Illustration 16shows a typical electrical connection to RS-232devices.

Table 11

RS-232 Port Characteristics

Parameter Value

Maximum Length of the Cable 30.5 m (100 ft)

Maximum Capacitance for the Cable from one Conductorto another Conductor(1) .002 µF

Maximum Resistance of the Cable for a single Conductor (2) 25 Ω(1) In order to measure capacitance of the cable, disconnect all devices from the network at the device. The wires for the network must beopen between the two conductors. Measure the capacitance between the two wires.

(2) In order to measure the resistance of the cable, disconnect all devices from the network at the device. The wires for the network mustbe open between the two conductors. Short the wires together at the PL1000E Communication ECM device. Measure the resistancebetween the two wires at each of the other devices. For the maximum reading taken, divide the resistance measurement by 2 andcompare to the value shown.

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Additional RS-232 device connection information toconsider:

• Either 16 AWG or 18 AWG wire should be used forall RS-232 serial port connections and harnessing.



• Each device that is installed must have powersystem connections that share a common ground(BATT-).


Wiring Requirements for Ethernet

The Ethernet communications connection providesa connection between the PL1000E and Ethernetdevices. The connection must conform to EIA 568-Astandards. The connection must be able work withany Ethernet device that also conforms to EIA 568-Astandards.

A minimum of “Category 5” Ethernet cable that meetsANSI/EIA/TIA-568-A building wiring standards mustbe used when connecting to PL1000E. The “CAT 5”rating will be printed on the jacket of the cable. A“Category 5” cable will meet specified requirementsregarding loss and induction of undesired signals.There are restrictions on the maximum cable lengthfor both 10 and 100 Mbits per second networks.

The following list is additional information that mustbe considered for connection of the Ethernet devices:



• Each device that is installed must have powersystem connections that share a common ground(BATT-).


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Building the Custom Harness Assembly

g01112044Illustration 17Connector Details for the ECM Harness(1) 160-7690 Connector(2) Allen Head Bolt(3) 8T-8737 Seal Plug

(4) 126-1768 Connector Socket (14AWG) or 9X-3402 Connector Socket(16-18 AWG)

(5) Wire showing stripped length

1. Refer to Illustration 17 and Illustration 5 to matchthe correct wires on the harness to the correctsocket positions on the connector.

2. Locate the sealing plugs that will need to beremoved from the connector. Use a fully insulatedpiece of 18 AWG wire as a tool in order to pushthe sealing plugs through the connector body fromthe front side of the connector.

3. Strip 7 mm (0.275 inch) of insulation from theend of each wire that is to be installed into theconnector.

Note: Ensure that the wires are the correct gauge forthe intended application.

4. Crimp a socket onto the end of each stripped wire.

5. Locate the correct position on the connector,then push the socket, with attached wire, into theconnector body from the rear of the connectoruntil fully seated.

6. Repeat Step 5 for each wire and socket that is tobe installed into the connector.

Connecting the Harness Assembly to thePL1000E Communication ECM

1. Place the 160-7690 Connector Plug As, a 70 pinconnector, of the harness assembly onto the ECMconnector.

2. Tighten the connector bolt with a 4 mm (5/32 inch)Allen wrench.

Connecting the Custom Harness to theSystem

Consult the system schematics for the specificapplication for information which will aid in theconnection of the custom harness into the system.

ECM Template

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©2008 CaterpillarAll Rights Reserved

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edgetrade dress, as well as corporate and product identity used herein, are trademarksof Caterpillar and may not be used without permission.

Printed in U.S.A.

17 december 2008 special instruction · 17 december 2008 special instruction i03297929 installation...

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