Ecm Pl1000e Installation Guide

Special Instruction
Installation Guide for the 256-7512 PL1000E Communications ECM {7610}

Installation Guide for the 256-7512 PL1000E Communications ECM
{7610}
SMCS - 7610
Electric Power Generation: All
Engine:Industrial, Marine, and Generator Set that Use Flash Programming All
Introduction
This Special Instruction provides information for the installation of the 256-7512 PL1000E Communication ECM .
Refer to Systems Operation, RENR8091 for more information about the 256-7512 PL1000E Communication ECM .
Do not perform any procedure that is outlined in this publication, or order any parts until you understand this
information.
Required Tools
The following tools will be required to install the 256-7512 PL1000E Communication ECM . The list below contains
the recommended Caterpillar service tools.
Shutdown SIS

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Media Number -REHS2362-00 Publication Date -01/06/2005 Date Updated -28/06/2005

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Table 1
Part Number Description
Laptop Computer
J ERD2124 Caterpillar Electronic Technician (CAT ET) Version 2004B or later
J ERD2129 Date Subscription for all engines and machines
EERP1000 Caterpillar Tool Kit Version 2005A or later
171-4400 Communication Adapter Gp (CAT ET TO ECM INTERFACE) (optional)
(1)

9U-7330 Digital Multimeter
7X-1710 Multimeter Probe
1U-5804 Crimp Tool (12-AWG TO 18-AWG)
Parts List
Additional Parts that may be needed
For most applications the 276-0785 Harness Assembly will require additional wiring. Table 3 lists optional
components that may be needed in order to complete the wiring for the intended application.
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 ECM's embedded communication adapter may also be used.
( 2 )
Two short jumper wires are needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together
in a connector.
( 3 )
A long extension wire may also be needed to check the continuity of some wiring harness circuits.
Table 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 Rubber Bumper
(1)

4 129-3178 Locknut
1 256-7512 PL1000E Communication ECM with Flashed application software
1 276-0785 Harness Assembly
1 228-6559 Harness Assembly
( 1 )
Self stick adhesive back. Applied to the bottom of the ECM when shock mounting is not required. For use when mounting the ECM on a
table or desk only.
Table 3
Additional Wiring Components
1-70 9X-3402 Connector Socket (16 AWG - 18 AWG)
1-70 126-1768 Connector Socket (14 AWG)
Some installations may require additional mounting hardware to secure the ECM to a mounting surface. These
installation methods are detailed in Section ""ECM Module Installation" ". Table 4 lists optional components for
ECM mounting.
ECM Mounting Considerations
Identify a mounting location for the ECM. Measure the location to ensure correct spacing for the ECM "footprint"
and harness routing.
Determine the appropriate mounting method (shock mount or desk mount), for your specific application.
1-3 163-5620 Plug Assembly (DB-9 Style)
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 J 1939 Terminating Resistor
199-9785 Wire Assembly - Splice
207-3814 Wire Assembly - Splice
115-8109 Wire Splice (Single Sealed)
Table 4
Additional ECM Mounting Components
4 Various M6 x 1 bolt or weld stud (length varies depending on mounting method)
4 Various M6 x 1 weld boss, nut, or similar fastener
NOTICE
For mounting applications where the ECM may be subjected to shock
or vibration, use the shock mounting method. Use the desk mounting
method for mounting applications where the ECM will not be exposed
to shock or vibration.
When mounting the ECM, orient so that the ECM connector is not
subjected to high pressure spray or underwater submersion. Exposure
to high pressure spray or underwater submersion may compromise the
connector seal and lead to connection failure.
When mounting the ECM, orient so that the ECM is not used as a
ECM Module Installation
Desk Mounting Method
1. When mounting the ECM on a stable surface such as a table or desk, apply the four 117-1660 Rubber Bumpers
to the bottom side of the ECM at each corner. The bottom side of the ECM is the side opposite of the ECM
connector.
2. Place the ECM in the desired location on a flat level surface.
Shock Mounting Method
There are several different methods for shock mounting the ECM. Select a shock mounting method that is appropriate
for the intended application and environment.
Preferred Shock Mounting Method using weld bosses or weld studs
The preferred shock mounting method requires the use of weld bosses or weld studs to mount the ECM. Refer to
Illustrations 1 and 2.
1. Locate the ECM mounting hole template (Illustration 17) and place the template in the desired ECM mounting
location.
2. Mark each mounting hole location.
3. Remove the template.
4. Weld the weld bosses or weld studs at the marked locations.
5. Mount the ECM onto the weld bosses or weld studs as shown in Illustration 1 or Illustration 2.
6. Tighten the bolts or locknuts to 12 Nm (9 lb ft).
"boot step" or a fulcrum point for a dealer mechanic or tradesperson.
The ECM is made of a high strength cast aluminum, but can still be
damaged.

Illustration 1 g01111540
Shock Mounting Method using 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

Shock Mounting Method using weld studs
(2) M6 x 1 Locknut
Shock Mounting Method using bolts and threaded mounting holes
Shock mounting the ECM using threaded mounting holes requires the use of drilled and tapped holes to mount the
ECM. Refer to Illustration 3.
location.
4. Drill a 4 mm (11/64 inch) hole at each marked location.
5. Tap each hole with a M6 x 1 tap to provide the threaded holes for the M6 x 1 bolts.
6. Mount the ECM as shown in Illustration 3.
7. Tighten the bolts to 12 Nm (9 lb ft).
(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 Method using 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
Shock Mounting Method using bolts and through holes
Shock mounting the ECM using through holes requires drilling four clearance holes for mounting the ECM. Refer to
Illustration 4.
location.
4. Drill a 6.35 mm (0.25 inch) hole at each marked location.
5. Mount the ECM as shown in Illustration 4.
6. Tighten the bolts to 12 Nm (9 lb ft).
(6) Mounting plate

Shock Mounting Method using through holes
(2) M6 x 1 Locknut
(3) 9X-6165 Washer
(4) 8C-5608 Spacer
(5) 8C-5607 Mount
Wiring Requirements and Installation
The 276-0785 Harness Assembly is supplied to provide the basic power and communications with the 256-7512
PL1000E Communication ECM . The harness connectors are shown in Table 5.
ECM Connector and Wiring Harness Pin-out
(6) Mounting plate
(7) M6 x 1, bolt - Length =43 mm +mounting plate thickness
Table 5
Connector
Part
Number

Description
ECM
160-7690

70-pin AMP rectangular plug. Provides the connection to the PL1000E
Communication ECM.
Power
3E-3376

4-pin Duetsch DT style rectangular receptacle. The connector provides ready access to
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 tool
connector found on most Caterpillar machine and engine connections for use with the
171-4400 Communications Adapter II or similar communications device. The
communications device is connected to a PC serial port or parallel port allowing the
PC to communicate with the CAT Data Link network or the J 1939 #1 network using
standard Caterpillar tools such as CAT ET.
Embedded
Comm
Adapter
257-2719

9-pin AMP DB style plug. The connector provides a similar function as the Service
Tool connector expect that the connector can plug directly into a PC rather than
having to go through a 171-4400 Communications Adapter II or similar device. Refer
to the section "Embedded Comm Adapter Connectin Group" in Table 6 for more
information.
NOTICE
The technician must provide additional wiring in order to complete the
installation of the ECM into a custom communciation system. The 276-
0785 Harness Assembly electrical diagram is shown in Illustration 5.
The wiring of individual power and communications circuits is detailed
in subsequent sections.

Refer to Illustration 5 for possible connections that can be made to the 256-7512 PL1000E Communication ECM for

specific applications. The Connection Groups shown in Illustration 5 are described in Table 6. Use only the
Connection Groups necessary for your specific application.
Note: Most of these Connection Groups require special configurations of the 256-7512 PL1000E Communication
ECM using one of the service tools in Table 1. Refer to System Operation, RENR8091 for specific information about
these special configurations.
System Power Wiring Requirements
Table 6
Connection Group Applications
System Power
Connection Group
The System Power Connection Group provides a standard Electronic Control power
connection between system power and the ECM. Refer to the section ""System Power
Wiring Requirements" " for specific wiring requirements.
CAT Data Link
(CDL) Connection
Group
The CAT Data Link Group provides a standard CAT Data Link connection. This
connection must be used when implementing the PL1000E Communication ECM's
Embedded Communications Adapter (ECA) feature to service a CDL-compatible device
using standard Caterpillar service tools, such as CAT ET. Refer to the section ""Cat Data
Link Communications Wiring Requirements" " for specific wiring requirements.
J 1939 Network
Connection Group
The J 1939 Network Connection Group provides a standard CAN bus connection operating
at 250,000 baud. The J 1939 Network Connection Group must be connected in order to
implement the PL1000E Communication ECM's J 1939 Bridge or CAN Extension Bridge
features. Additionally, the J 1939 Network Connection Group may also be connected in
order to facilitate connections to J 1939 compatible devices using the PL1000E
Communication ECM's Embedded Communications Adapter feature for standard
Caterpillar service tools, such as CAT ET. Refer to "SAE J 1939-11", "SAE J 1939-15", and
the section ""J 1939 Communications Wiring Requirements" " for specific wiring
requirements.
RS-485 Network
Connection Group
The RS-485 Connection Group is capable of providing an RS-485 or RS-422 4-wire
connection that can be used for Modbus communications. The PL1000E Communication
ECM must be configured for the appropriate protocol and baud rate. Refer to Service
Manual, RENR8091, "ECM - Configure" for available configuration values.
RS-232 Serial
Connection Group
#1
&
RS-232 Serial
Connection Group
#2
The RS-232 Serial Connection groups provide a standard RS-232 serial interface
programmable to operate in the range of 4800 to 115200 baud. These serial connection
groups correspond to the PL1000E Communication ECM Serial Ports #1 and #2
respectively. Refer to the section ""RS-232 Communications Wiring Requirements" " for
specific wiring requirements.
Embedded
Communications
Adapter Connection
Group
The Embedded Communications Adapter Connection Group provides a standard RS-232
serial interface that can operate anywhere in the range of 9600 baud through 115K baud.
The Embedded Communications Adapter Connection Group must be connected in order to
implement the PL1000E Communication ECM's Embedded Communications Adapter
feature. The Embedded Communications Adapter feature allows standard Caterpillar
service tools, such as CAT ET to interface with a CDL device or J 1939 device.
Ethernet Connection
Group
The Ethernet Connection Group provides an interface for use with Modbus TCP,
embedded web pages, and FTP. This connection group may be installed for either a
network connection or a cross over direct connection.
The power connector in the 276-0785 Harness Assembly provides a direct connection to the PL1000E
Communication ECM's switched power inputs and un-switched power inputs.
Basic power connection parameters are shown in Table 7. Basic electrical connections are shown for single power
sources in Illustration 6. Basic electrical connections are shown for multiple power sources in Illustration 7.
NOTICE
The 276-0785 Harness Assembly contains 218-4935 Arc Suppressors to
protect the internal circuitry of the 256-7512 PL1000E Communication
ECM from high voltage transients. DO NOT remove these transient
devices from the 276-0785 Harness Assembly or rewire the system to
remove the transient devices from the wiring. Doing so will void the
warranty on the 256-7512 PL1000E Communication ECM .
Table 7
Basic Power Connection Parameters
Parameter
Value
Min Nominal Max
Voltage between BATT+and BATT- 9V 12V or 24V 32V
Current Draw
(1)
0.5A 5A
( 1 )
Provide fuse protection for the BATT+and KEYSW to not allow the current to exceed 5 Amps

Power Connection - Single Power Source

Additional power connection information to consider:
Minimum 18 AWG wire should be used for KEYSW, BATT+, and BATT- connections and harnessing.
The Key Switch connection "activates" the PL1000E Communication ECM. If a key switch does not exist in
the electrical system, or if it is desired to have the PL1000E Communication ECM powered at all times, then
connect the KEYSW connection directly to BATT+.
The BATT- must connect to a ground signal common with the rest of the system components obtaining voltage
from the same power supply. Grounding requirements may vary from application to application. Consult your
system's schematics and other system documentation for grounding requirements.
Provide fuse protection for BATT+and KEYSW to not allow the current to exceed 5 Amps.
Provide diode isolation where multiple power sources are used. The diodes isolate the power sources allowing
the PL1000E Communication ECM to remain powered if at least one power source is operational.
Use good wire routing and wire securing practices to avoid damage to the cable.
Run cable away from high power and high frequency sources to avoid injecting electrical noise into the wiring.
Install sealing plugs (8T-8737) into any unused sockets at the rear of the connector.
CAT Data Link Communications Wiring Requirements
The CAT Data Link Communications connection provides a connection between the PL1000E Communication ECM
and the CAT Data Link network. The PL1000E Communication ECM can connect close to the system (Boost
Disabled) with a total network wiring length of 33 m (100 ft), or locate a distance away from the system (Boost
Enabled) with a total network length of up to 330 m (1000 ft). These wiring distances are dependant on wire gauge,
wire resistance, and cable capacitance. Reference Table 8 for specific wiring requirements and basic parameters.
Basic electrical connections are shown in Illustration 8 and Illustration 9.

Power Connection - Multiple Power Source
Table 8
Cat Data Link Port Characteristics
Parameter Value
CDL Boost Disabled CDL Boost Enabled
Maximum Cable Length
(1)

30 m (100 ft) 16 AWG
wire

300 m (984 ft) 18 AWG
wire
Maximum Cable
Capacitance
(2)

Conductor to
Conductor
.0023 F .035 F
Conductor to Shield .0044 F .006 F
Maximum cable resistance for a single conductor
(3)
0.43 Ohms 6.5 Ohms
Maximum number of devices
(4)
11 11
( 1 )
This length is the total length of all wiring in the Cat Data Link network, including the wiring for the ECM. Refer to Illustration 10 for
explanation of how to properly calculate cable length.
( 2 )
To measure cable capacitance, disconnect all devices from the network at the device connection such that the network wires are open
between the two conductors. Measure the capacitance between the two wires.
( 3 )
To measure cable resistance, disconnect all devices from the network at the device connection such that the network wires are open
between the two conductors. Short the wires at the PL1000E Communication ECM device connection. Measure the resistance between
the two wires at all other device connections. For the maximum reading taken, divide the resistance measurement by 2 and compare to
the value shown.
( 4 )
This is the number of devices on the network including the PL1000E Communication ECM.

Typical CAT Data Link Communications Wiring-Using Service Tool Connector

Additional Cat Data Link connection information to consider:
Connecting to the Cat Data Link network is NOT necessary for operation of the PL1000E Communication
ECM.
Connecting multiple Cat Data Link networks together, without properly configuring the ECMs on the networks,

Typical CAT Data Link- Splicing into 276-0785 Harness Assembly

may cause communications conflicts among the ECMs and possible shutdown of the engines or other devices
controlled by the ECMs.
If connecting to a Cat Data Link network, connect to one network only.
16 AWG or 18 AWG common harness wire should be used for wiring the Cat Data Link network as a twisted
pair with 1/3 to 1 full twist per inch.
Each ECM installed on the Cat Data Link network should have power system electrical connections such that
they all share a common ground (BATT-).
J1939 Communications Wiring Requirements
The J 1939 Communications connection provides a connection between the PL1000E Communication ECM and the
J 1939 network. The J 1939 network contains a bus along with stub wiring to connect nodes to the bus. The bus is
terminated on each end to complete the network. Table 9 shows the parameters for the J 1939 network and Illustration
11 shows a typical J 1939 network layout. Illustration 12 and Illustration 13 show electrical connection methods for
J 1939.
Table 9
J1939 Port Characteristics
Parameter
Value
Shielded (SAE J1939-11) Unshielded (SAE J1939-15)
Maximum Nodes (n) 30 10
Maximum Bus Length
(1)
(L)

40 m (132 ft)
Maximum Stub Length
(2)
(S)

1 m (3.3 ft)

3 m (9.8 ft)
Node Distance (d) 0.1 m - 40.0 m (0.3 ft - 98.5 ft)
Minimum distance to terminating resistor (d
0
)
0.0 m
Terminating Resistors (R
T
)
120 Ohms, 0.5 Watt
( 1 )
Do not include cable stubs in your calculations.
( 2 )
Subtract 0.33 meters if the cable stub is for a service port connector.

Typical J 1939 Communications Network Layout

J 1939 Communications Wiring - Using Service Tool Connector

Additional J 1939 connection information to consider:
A terminating resistor must be connected to both ends of the J 1939 communications bus for proper operation of
the network.
16 AWG or 18 AWG common harness wire should be used for wiring the J 1939 network as a twisted pair with
1 full twist per inch.
Each device installed on the J 1939 network should have power system electrical connections such that they all
share a common ground (BATT-).
RS-485 Harness Requirements
The RS-485 Communications connection provides a connection between two PL1000E Communication ECMs in a
CAN Extension Bridge configuration. The basic parameters are shown in Table 10. Basic electrical connections are
shown in Illustration 14.

J 1939 Communications Wiring - Alternate Routing of 276-0785 Harness Assembly
Table 10
RS-485 Port Characteristics
Additional RS-485 connection information to consider:
16 AWG or 18 AWG common harness wire should be used for wiring the RS-485 network.
Each device installed on the RS-485 network should have power system electrical connections such that they
all share a common ground (BATT-).
RS-232 Wiring Requirements
The RS-232 Communications connection provides a connection between the PL1000E Communication ECM and RS-
232 devices. The connection conforms to EIA RS-232 standards and will work with any RS-232 devices that also
conform to EIA RS-232 standards. Table 11 shows the parameters for the RS-232 Device connections and Illustration
15 shows a typical electrical connections to RS-232 devices.
Parameter Value

305 m (1000 ft)
Maximum Conductor to Conductor Cable Capacitance
(1)
.022 F
Maximum Cable Resistance for a single Conductor
(2)
39 Ohms
( 1 )
( 2 )
the value shown.

Additional RS-232 device connection information to consider:
Either 16 AWG or 18 AWG wire should be used for all RS-232 Serial Port connections and harnessing.
Each device installed should have power system electrical connections such that they all share a common
ground (BATT-).
Table 11
RS-232 Port Characteristics
Parameter Value

30.5 m (100 ft)
Maximum Conductor to Conductor Cable Capacitance
(1)
.002 F
Maximum Cable Resistance for a single Conductor
(2)
25 Ohms
( 1 )
( 2 )
the value shown.

Building the Custom Harness Assembly
1. Refer to Illustration 16 and Illustration 5 to match the correct wires on the harness to the correct socket
positions on the connector.
2. Locate the sealing plugs that will need to be removed from the connector. Then, using a fully insulated piece of
18 AWG wire as a tool, push the sealing plugs through the connector body from the front side of the connector.
3. Strip 7 mm (0.275 inch) of insulation from the end of each wire that is to be installed into the connector.
Note: Ensure that the wires are the correct gauge for the intended application.
4. Crimp a socket onto the end of each stripped wire.

Harness ECM connector details
(1) 160-7690 Connector
(2) Allen bolt
(3) 8T-8737 Seal Plug
(4) 126-1768 Connector Socket (14 AWG) or 9X-3402 Connector Socket (16-18 AWG)
(5) Wire showing stripped length
5. Locate the correct position on the connector and push the socket (with attached wire) into the connector body
(from the rear of the connector) until fully seated.
6. Repeat Step 5 for each wire and socket that is to be installed into the connector.
Connecting the Harness Assembly to the PL1000E Communication ECM
1. Place the 160-7690 70-pin Connector of the harness assembly onto the ECM connector.
2. Tighten the connector bolt with a 4 mm (5/32 inch) Allen wrench.
Connecting the Custom Harness to the System
Consult your application's system schematics for information which will aid in the connection of the custom harness
into the system.
ECM Mounting Hole Template

Copyright 1993 - 2005 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 9 08:50:08 CDT 2005

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Special Instruction

Installation Guide for the 256-7512 PL1000E Communications ECM {7610}

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