Installation Guide for the Machine Security System on Skid Steer Loaders and Multi Terrain Loaders{7631} Caterpillar

Multi Terrain Loader:

247B (S/N: MTL1-UP)

257B (S/N: SLK1-UP)

267B (S/N: CYC1-UP)

277B (S/N: MDH1-UP)

287B (S/N: ZSA1-UP)

Skid Steer Loader:

216B (S/N: RLL1-UP)

226B (S/N: MJH1-UP)

232B (S/N: SCH1-UP)

236B (S/N: HEN1-UP)

242B (S/N: BXM1-UP)

246B (S/N: PAT1-UP)

248B (S/N: SCL1-UP)

252B (S/N: SCP1-UP)

262B (S/N: PDT1-UP)

268B (S/N: LBA1-UP)

Introduction

This Special Instruction provides information for installation of the 239-5010 Security Installation Gp (KIT). The operation of the Machine Security System is covered in the Systems Operation, RENR2462, "Machine Security System (MSS)". Refer to that manual for more information.

Do not perform any procedure that is outlined in this publication, or order any parts until you understand this information.

Note: Before you install the Machine Security System on a machine, check for other electronic control modules on the machine. Machines that are equipped with other electronic control modules must NOT use the Machine Security System to disable the "MAIN POWER" of the machine. This will prevent the Machine Security System from disabling the other electronic control modules on the machine in the event of a failure of the Machine Security System.

Required Tools

The following tools will be required to install the Machine Security System. The list below contains the recommended Caterpillar service tools.

Parts List

Installation Procedure

Machine Disassembly

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Batteries give off flammable fumes which can explode. To avoid injury or death, do not strike a match, cause a spark, or smoke in the vicinity of a battery.

1. Disconnect the grounded battery cable from the battery. Position the grounded battery cable so the cable cannot contact any of the battery posts.

2. Release the hydraulic system pressure.

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Do not go beneath cab unless cab is empty and support lever is engaged. Failure to follow the instructions or heed the warnings could result in injury or death.

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Do not tilt the cab using an open door. The door must be closed and latched when lifting the cab. The door may become dislodged from its hinges and may cause serious personal injury or death.

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Illustration 1	g01093580
Location of the 2 front bolts for the ROPS.

3. Remove the two front bolts for the ROPS.

4. Close the cab door and ensure that the door is latched.

5. Tilt the cab upward. Stand on the ground when you tilt the cab.

   Note: More than one person may be needed to tilt the cab.

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Illustration 2	g00954946
Location of the cab support lever.

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Illustration 3	g00952728
The cab support lever is in the ENGAGED position.

6. Move the cab support lever to the ENGAGED position.

Mounting the MSS ECM-with Mounting Studs

Note: Ensure that the isolation mounts and spacers are installed onto the ECM before mounting the ECM onto the machine.

Illustration 4	g01092681
Mounting the MSS ECM with Mounting Studs.

1. Using the kit provided, place the isolation mounts and spacers onto the ECM.

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Illustration 5	g01094917
Cab location for mounting ECM.

2. Place the ECM onto the mounting studs present on the machine.

3. Place a washer over mounting stud.

4. Place the ECM ground strap over mounting stud. For the two mounting studs without an ECM ground strap proceed to Step 5.

5. Place a ladder clip over mounting stud.

6. Place a nut on mounting stud and tighten.

7. Repeat Step 3 through Step 6 for the remaining two mounting studs.

Mounting the MSS ECM-without Mounting Studs

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Illustration 6	g01094634
Installing the Insert Nuts into the hexagonal mounting holes.

1. Using the kit provided, assemble a bolt, spacer, two washers, and an insert nut as shown in Illustration 6.

2. Place into one of the three hexagonal mounting holes until fully seated in the hole.

3. Hold firmly and tighten the bolt until the insert nut expands and is firmly held in the hexagonal mounting hole.

4. Repeat Step 1 through Step 3 for the remaining mounting bolts.

5. Remove all three mounting bolts (with washers and spacers) from the insert nuts. The insert nuts will remain firmly held in the hexagonal mounting holes.

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Illustration 7	g01092925
Mounting the MSS ECM without Mounting Studs.

Note: Ensure that the isolation mounts and spacers are installed onto the ECM before mounting the ECM onto the machine.

6. Place the isolation mounts and spacers onto the ECM.

7. Place a ladder clip onto mounting bolt.

8. Place the ECM ground strap onto mounting bolt. For the two mounting bolts without an ECM ground strap, proceed to Step 9.

9. Place a washer onto mounting bolt.

10. Insert bolt (with ladder clip, ground strap, and washer) through the spacer and isolation mounts on ECM.

11. Place a washer onto mounting bolt between isolation mount and insert nut.

12. Tighten bolt.

13. Repeat Step 7 through Step 12 for the remaining two mounting bolts.

Installation of the 216-4709 Harness Assembly

1. Using the kit provided, connect the two 2-pin connectors of the 222-3870 Ferrite Coil Assembly to the two 2-pin connectors of the 216-4709 MSS Harness Assembly .

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Illustration 8	g01093099

2. Secure the 222-3870 Ferrite Coil Assembly to the 216-4709 MSS Harness Assembly with the 7K-1181 Cable Straps .

3. Connect the 70-pin connector of the 216-4709 MSS Harness Assembly to the 70-pin connector on the 156-6155 MSS ECM .

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Illustration 9	g01094748
The 12-pin connector (with 12-pin jumper receptacle) is located on the left side of the machine near the down tube from Oil Tank.

4. Locate the 12-pin connector on the machine and remove the 12-pin jumper receptacle. Refer to Illustration 9.

5. Attach the 12-pin receptacle of the 216-4709 MSS Harness Assembly to the 12-pin connector on the machine.

6. Locate the 4-pin connector on the machine and remove the sealing receptacle. Refer to Illustration 8.

7. Attach 4-pin receptacle of the 216-4709 MSS Harness Assembly to the 4-pin connector on the machine.

8. Use the 7K-1181 Cable Straps to secure the harness back to the 12-pin connector shown in Illustration 9.

9. Use the 7K-1181 Cable Straps to secure the harness back to the MSS ECM shown in Illustration 8.

10. Ensure that no one is underneath the cab. Remove all tools and unsecured items from underneath the cab.

11. Tilt the cab upward. Stand on the ground when you tilt the cab.

    Note: More than one person may be needed to tilt the cab.

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Illustration 10	g00954946
Location of cab support lever.

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Illustration 11	g00952719
The cab support lever is shown in the DISENGAGED position.

12. Move the cab support lever to the DISENGAGED position.

13. Carefully tilt the cab downward.

    Note: Make sure that all cable straps are installed correctly in order to prevent harness vibration and in order to prevent the harness from rubbing against other parts.

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Illustration 12	g01093580

14. Tighten the bolts that secure the cab to the chassis.

Installation of the Exciter Coil

1. Inside the cab, remove the left side overhead console containing the key switch.

   Note: You may need to remove the left hand window in order to remove the upper right hand overhead console.

2. Remove the key switch nut.

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Illustration 13	g00783001
Key switch with exciter coil template installed.

3. Locate the template for the exciter coil (Illustration 19) and install the template over the key switch as shown in Illustration 13. To aid in the proper orientation of the template:

   1. Install the template over the key switch. Install with the 10 mm (0.375 inch) hole directly below the 25.4 mm (1 inch) hole.

   2. Rotate the template clockwise approximately 45°. Refer to Illustration 13.

4. Replace the key switch nut. Hand tighten.

5. Mark the drill site with a center punch.

6. Remove the key switch nut and remove the template.

7. Remove the back of the left side overhead console and remove the key switch.

8. Drill a 10 mm (0.375 inch) hole at the marked location.

   Note: Place a stop on the drill bit to prevent drilling depth of more than 7 mm (0.275 inch). This is to prevent damage to the machine harness and/or components.

9. Place the key switch back into the hole for the key switch.

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Illustration 14	g00909553
Front View of Exciter Coil.

10. Install the exciter coil over the key switch. Route the wires for the exciter coil through the 10 mm (0.375 inch) hole.

11. Reinstall the nut for the key switch and tighten to the proper specification.

12. Place wires for the exciter coil into a 102-8802 Receptacle Kit (2-PIN). The location of the pins does not matter.

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Illustration 15	g01095053
Left side overhead operator's assembly with rear of assembly removed.

13. Connect the 2-pin connector from the exciter coil to the 2-pin connector from the left side overhead console as shown in Illustration 15.

14. Re-assemble the left side overhead console containing the key switch and exciter coil.

15. Reinstall the left side overhead console onto the machine.

Installation of the LED Indicator

1. Inside the cab, remove the upper right hand overhead console.

   Note: You may need to remove the right hand window in order to remove the upper right hand overhead console.

2. Remove the back of the upper right hand overhead console.

3. Mark the LED indicator location 85 mm (3.35 inch) from the right edge of console and 90 mm (3.5 inch) from the bottom edge of console as shown in Illustration 16. Mark the site with a center punch.

   Note: Place a stop on the drill bit to prevent drilling depth of more than 6 mm (0.25 inch). This is to prevent any damage to the machine harness and/or components.

4. Drill a 13 mm (0.50 inch) hole at the marked location.

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Illustration 16	g01095084
Upper right hand console showing location of LED indicator.

5. Route the three LED indicator wires through the 13 mm (0.50 inch) hole. Install the LED indicator into the hole. Make sure that the LED indicator locks into place.

6. Place the wires of the LED indicator into the 102-8803 Receptacle Kit (3-PIN). The pin locations are as follows:
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   Table 3

   Wire Table for LED Indicator Connector
   A	Red Wire
   B	Black Wire with Green Cover
   C	Black Wire

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Illustration 17	g01095092

7. Locate the 12 pin plug at the back of the RH Lamp Group and unplug.

8. Remove the plug wedge and remove the following wires:
   • Pin 2 (200-BK)

   • Pin 4 (G848-GN)

   • Pin 8 (F846-PU)

9. Seal the back of the 12 pin plug by inserting the 8T-8737 Seal Plug in wire holes 4 and 8.

10. Insert a socket end of the 207-3814 Wire As. into the pin 2 location of the 12 pin plug.

11. Reapply the wedge to the 12 pin plug and reconnect to the RH Lamp Group.

12. Insert the pin end of the 207-3814 Wire As. into one end of the 115-8109 Sealed Splice .

13. Insert wire 200-BK (removed from 12 pin plug in Step 8) into the other end of the sealed 115-8109 Sealed Splice .

14. Insert the remaining wires into the 155-2260 Plug Kit as follows:
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    Table 4

    Wire Table for 155-2260 Connecting Plug Kit
    A	F846-PU
    B	G848-GN
    C	207-3814 Wire As. (socket end)

15. Insert the wedge into the plug.

16. Connect the 155-2260 Plug Kit to the 102-8803 Receptacle Kit (3-PIN) from the LED indicator.

17. Re-assemble the upper right hand overhead console.

18. Reinstall the upper right hand overhead console onto the machine.

19. Reconnect the grounded battery cable to the negative post of the battery.

Setup of the Machine Security System (All Machines)

Set up the Product Identification Number of the machine, date and time, and bypass schedule as described in Service Manual, RENR2462, "Machine Security System (MSS)"

1. Enter the machine's Product Identification Number according to the Product Identification Number - Program section of Service Manual, RENR2462, "Machine Security System (MSS)".

2. Set the current date, time, and the time zone according to the Time - Set section of Service Manual, RENR2462, "Machine Security System (MSS)".

3. Set the bypass schedule according to the System Disarm - Program - Security System Bypass section of Service Manual, RENR2462, "Machine Security System (MSS)".

Film Application and Operational Check (All Models)

1. Place a valid electronic key in the key start switch.

2. Turn the electronic key to the ON position until the green LED indicator turns ON.

3. Turn the key to the START position. The machine should start.

4. Turn the key to the OFF position.

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Illustration 18	g00920946

5. Apply the 198-5389 Film - Ignition Switch to the key switch. The OFF position must be at 12 o'clock. Refer to Illustration 18.

6. Install the 205-0826 Film - Machine Security System in a visible position in the cab as close as possible to the key switch. Refer to Illustration 18.

7. Apply the 225-5927 Film - Security (Machine Security System) to the LH side of the ROPS.

8. Reassemble all of the remaining parts and covers.

9. Attach Special Instruction, RMHS1002, "Operation of the Machine Security System (MSS)" to the machine's Operation and Maintenance Manual with the tape that is provided.

Template for the Exciter Coil

Illustration 19	g01005919
Measure the diameters of the holes in order to verify that the scale of the template is correct.