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

Skid Steer Loader:

216 (S/N: 4NZ1-2499)

226 (S/N: 5FZ1-5199)

228 (S/N: 6BZ1-699)

236 (S/N: 4YZ1-3999)

246 (S/N: 5SZ1-3999)

248 (S/N: 6LZ1-999)

Introduction

This Special Instruction provides information for installation of the 197-4605 Machine Conversion Group . The operation of the Machine Security System is covered in the Service Manual, 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 of the 197-1998 Machine Harness Assembly

Note: Use the 7K-1181 Cable Straps to secure retrofit harness away from moving parts as needed throughout this section.

1. Raise lift arms and lock into place.

Show/hide table

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.

2. Disconnect the grounded battery cable from the battery. Position the grounded battery cable so the cable can not make contact with any of the battery posts.

Show/hide table



Illustration 1	g00782948

3. Inside the cab, remove the left side overhead operator's assembly.

Show/hide table



Illustration 2	g00782993

4. On the main piece of the assembly, use the universal drill bit to drill a 19 mm (3/4 inch) hole (1) at the rear of the assembly. The location of the hole is to the right and slightly higher than the existing hole.

   Note: Prior to drilling, ensure there are no obstructions in drill path.

Show/hide table



Illustration 3	g00909553
Front view of the exciter coil

Show/hide table



Illustration 4	g00909554
Front view of the exciter coil and the key switch

5. Install the exciter coil around the key switch.

   1. Remove the key switch nut.
   Show/hide table
   
   

   Illustration 5	g00783001

   2. Install the paper template over the key switch.

      Note: The template for the exciter coil is located in the back of this manual.

   3. Replace the key switch nut. Hand tighten.

   4. Mark the drill site with a center punch. Refer to Illustration 5.

   5. Remove the key switch nut, template and key switch.

   6. Drill a 10 mm (3/8 inch) hole.

      Note: Place a stop on the drill bit to prevent drilling depth of more than 7 mm (1/4 inch). This is to prevent any damage to the machine harness and/or components.

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

   8. Install the exciter coil over the key switch. Route the wires for the exciter coil through the 10 mm (3/8 inch) hole. The exciter coil should be flush with the dash panel. Refer to Illustration 6.
   Show/hide table
   
   

   Illustration 6	g00829247

   9. Install the film on the exciter coil.

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

   11. Place wires for the exciter coil into a 2-pin connector receptacle. The location of the pins does not matter.

6. Install the LED indicator.

   1. Locate a position to install the LED indicator close to the key switch. Refer to Illustration 6.

   2. Mark the site with a center punch.

   Note: Place a stop on the drill bit to prevent drilling depth of more than 6 mm (1/4 inch). This is to prevent any damage to the machine harness and/or components.

   3. Drill a 13 mm (1/2 inch) hole at the marked location.

   4. Install the indicator lamp into the hole. Ensure that the lamp locks into place.

   5. Terminate the wires of the indicator lamp with the 102-8803 Receptacle Kit (3 pin) . The pin locations are as follows:
      Show/hide table

      Table 3

      Pin	Wire
      A	Red Wire
      B	Black Wire with Green Cover
      C	Black Wire

Show/hide table



Illustration 7	g00896390
LED indicator and connector

7. Connect the 3-pin receptacle of the indicator lamp to the mating connectors of the 197-1998 Machine Harness Assembly .

8. Connect the 2-pin receptacle of the exciter coil to the mating connectors of the 197-1998 Machine Harness Assembly

9. Route the 197-1998 Machine Harness Assembly along existing machine harness to the rear of the assembly.

10. The 197-1998 Machine Harness Assembly will route through the 19 mm (3/4 inch) hole that was made in the rear of the assembly. At this time, install the rubber grommet that is included in the installation kit around the 197-1998 Harness and place the grommet into the hole.

11. Reassemble the left-side overhead assembly.

Show/hide table



Illustration 8	g00783010

12. Route the retrofit harness (2) along existing machine harness to Connector 17. This is a 70-pin connector.

    Note: You may need to lift the cab and remove the white plastic inserts before the sockets will seat in the connector.

13. At Connector 17 (3), insert the loose wires from the 197-1998 Machine Harness Assembly into the connector as follows:
    Show/hide table

    Table 4

    Pin	Wire	Labeled
    66	T901-YL	A-T4
    67	T902-PK	A-T5
    68	F846-PU	A-T2
    69	G848-GN	A-T3
    70	201-BK	A-T1

Installation Procedure of the Machine Security System ECM and the 197-1999 Machine Harness Assembly

Show/hide table



Illustration 9	g00911047

1. Raise the cab assembly and lock the cab in place.

Show/hide table



Illustration 10	g00910883

2. Remove the four bolts that secure the right hand support assembly. Refer to Illustration 10.

Show/hide table



Illustration 11	g00910912

3. Push the right hand support assembly to the rear of the machine. Refer to Illustration 11.

Show/hide table



Illustration 12	g00783652

4. Remove the plate that separates the hydraulic compartment and the operator's platform (1) .
   Show/hide table
   
   

   Illustration 13	g00905303

   1. Remove the floor plate.
   Show/hide table
   
   

   Illustration 14	g00910917
   (4) Bolt and spacer (5) Washer (6) Isolation mounts for the ECM (7) Boss

   Note: Ensure that the isolation mounts and the spacer are on the ECM before you mount the ECM.

   2. Using the kit provided, attach the mounting hardware to the module. Place the isolation mounts and the spacers in the ECM.

   3. Place a washer over the bolt. Insert the bolt and washer through the isolation mounts and spacers.

   4. Tighten the bolts to the bosses.
   Show/hide table
   
   

   Illustration 15	g00910937

   5. Prepare the wall on the left hand side of the compartment for welding.

Show/hide table



Illustration 16	g00911058

5. Remove the paint on the area to be welded.

6. Tack weld the bosses to the wall of the compartment while the bosses are installed on the MSS ECM.

Show/hide table



Illustration 17	g00911074

7. Remove the MSS ECM and complete the welds on the bosses.

Show/hide table



Illustration 18	g00905561

8. Mount the MSS ECM to the wall of the compartment with the hardware that is provided.

Note: The following steps involve the routing and connecting of the 197-1999 Machine Harness Assembly .

Show/hide table



Illustration 19	g00896395
222-3870 Assembly (Ferrite Coil)

9. Connect the 222-3870 Assembly (Ferrite Coil) to the 2 pin connectors of the 197-1999 Machine Harness Assembly .

Show/hide table



Illustration 20	g00913941

10. Secure the ferrite coil to the MSS harness with the 7K-1181 Cable Straps .

11. Connect the 70-pin connector of the 197-1999 Machine Harness Assembly to the MSS module.

12. Route the 197-1999 Machine Harness Assembly under the hydraulic pump, to the left side of the machine.

Show/hide table



Illustration 21	g00783701

13. Follow the hydraulic lines behind the solenoids and back to Connector 12. (40-pin connector) (2)

14. At Connector 12, perform the following steps:

    1. Pull the following machine pins from C12.
       Show/hide table

       Table 5

       Pin	Wire
       1	403-GN
       25	306-GN
       8	308-YL
       33	102-RD

    2. Place the machine wires into the 102-8804 Receptacle Kit (4-pin) as follows:
       Show/hide table

       Table 6

       Pin	Wire
       1	102-RD
       2	403-GN
       3	308-YL
       4	306-GN

    3. Connect the 4-pin receptacle to the 4-pin plug of the 197-1999 Machine Harness Assembly .
    Show/hide table
    
    

    Illustration 22	g00829254

    4. Insert loose contacts from retrofit harness into Connector 12 replacing pins pulled previously in step 14.a as follows:
       Show/hide table

       Table 7

       Pin	Wire	Labeled
       1	403-GN	A-T4
       25	307-OR	A-T3
       8	308-YL	A-T2
       33	105-RD	A-T1

    5. Reconnect Connector 12.

15. Install the Service Connector (CAT Data Link)
    Show/hide table
    
    

    Illustration 23	g00906133
    Service connector and relay connection

    1. Route small breakout of retrofit harness consisting of the service connector and the 2-pin connector for the main power relay into the engine compartment to the service connector. The service connector is located on the relay panel.

    2. Remove the existing service connector (A-C23) from the mounting site.

    3. Attach service connector (A-C23) to the mating connector of the 197-1999 Harness .

    4. Mount the secondary service connector of the 197-1999 Machine Harness Assembly to the mounting site in step 15.b.

    5. Remove the machine harness connector from the main power relay.

    6. Connect the 2-pin connector of the MSS harness to the connector of the main power relay. The machine harness connector for the main power relay remains disconnected. Secure the loose machine harness connector for the main power relay.

16. Route remaining retrofit harness from C12, up along existing machine harness, to the hydraulic control module, and the back to Connector 17 (C17).

17. Perform the following steps at C17.

    1. Attach the ECM ground wire to the ground terminal of the machine. This is located next to C17.
    Show/hide table
    
    

    Illustration 24	g00829260

    2. Insert remaining retrofit pins of the 197-1999 Machine Harness Assembly into Connector 17 as follows:
       Show/hide table

       Table 8

       Pin	Wire	Labeled
       66	T901-YL	A-T9
       67	T902-PK	A-T10
       68	F846-PU	A-T7
       69	G848-GN	A-T8
       70	201-BK	A-T6

    3. Ensure all the pins in Connector 17 are locked in place.

    4. Reconnect Connector 17.

Show/hide table



Illustration 25	g00912901
Connections for the MSS harness

18. Secure the 197-1999 Harness with the 7K-1181 Cable Straps

19. Lower the cab assembly and lock the cab in place.

Show/hide table

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.

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

21. Install the MSS film in a visible position in the cab as close as possible to the key switch. Refer to Illustration 6

Illustration 26	g00942815
MSS film

Setup of the Machine Security System (All Machines)

Setting the Product Identification Number of the Machine

The following procedure allows you to input/change the Product Identification Number ("Product ID").

1. Connect the ET to the service connector via the communication adapter.

2. Place the Master Access Level Key into the key start switch and turn the key to the ON position.

3. Start the ET and click on the "Connect" icon in the menu bar of the ET to start communications with the MSS ECM.

4. Select the "Configuration" option from the "Service" Menu. This will display the "Configuration" screen.

Show/hide table



Illustration 27	g00827547

5. Select the "Product ID" selection that is displayed on the "Configuration" screen.

6. Click on the "Change" button that is located on the "Configuration" screen. This will display a dialog box.

Show/hide table



Illustration 28	g00827548

7. Enter the "Product ID" of the machine. Refer to Illustration 29 for the proper format of the Product Identification Number.

Note: The First Quarter of 2001, the Caterpillar Product Identification Number (PIN) changed from 8 characters to 17 characters. The "Product ID" that is required by the Machine Security System is Item (4) in Illustration 29.

Show/hide table



Illustration 29	g00860618
(1) Caterpillar's World Manufacturing Code (characters 1 - 3). (2) Machine descriptor (characters 4 - 8) (3) Check character (character 9) (4) Machine Indicator Section (MIS) or Product Sequence Number (characters 10 - 17). These characters were previously referred to as the Serial Number.

8. Click on the "OK" button. This will cause the ET to display the following message.

Show/hide table



Illustration 30	g00827549

9. Click on the "Yes" button to change the Product ID or click on the "No" button to cancel the change.

   If you enter an invalid "Product ID", the ET will display the following message:

Illustration 31	g00827550

Set the Time and the Date

It is necessary to set the correct time and the date for the Machine Security System. Use the following procedure to set the time and the date.

1. Connect the ET to the service connector via the communication adapter.

2. Place the Master Access Level Key into the key start switch and turn the key to the ON position.

3. Start the ET.

4. Click on the "Connect" icon in the menu bar of the ET.

5. Once the ET has established communications with the MSS ECM, select the "ECM date/time" option from the "Service" menu. This will cause the ET to display the following screen.

Show/hide table



Illustration 32	g00827585

6. Press the "Change" button.

Show/hide table



Illustration 33	g00827586

7. Enter the correct time and the date and press the "OK" button. Then, the ET will display the following message.

Show/hide table



Illustration 34	g00827587

8. Click on the "Yes" button in order to change the date/time clock or click on the "No" button in order to cancel the change.

9. Perform the ""Operational Check (All Models)" ".

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.

5. Disconnect the grounded battery cable from the battery.

6. Reassemble all of the remaining parts and covers.

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

8. Attach the 225-5927 Machine Security System Film to the door of the machine or on the ROPS near the mount or dismount route of the operator. This film should be attached to a painted surface if possible.

9. Reconnect the grounded battery cable to the battery.

Troubleshooting (All Machines)

The machine fails to start

Indicator light does not turn on

Verify that all connections are tight.

Check the indicator light.

Indicator light remains red

The indicator is red for five seconds after attempting to start the machine. This indicates one of the following problems:

• The key in the key start switch is not authorized for that machine. Refer to Service Manual, RENR2462, "Machine Security System (MSS)", "Key - Program".

• The Remote Key Reader is not working properly. Check the resistance of the wiring for the Remote Key Reader. Also, check the resistance of the Remote Key Reader.

Indicator light becomes green but the engine will not start

The indicator light displays a green light for 30 seconds after you attempt to start the machine. This indicates that the Machine Security System has recognized a valid key for the machine. Ensure that all of the standard starting requirements for the machine have been met. Examples of the starting requirements include: interlocks in the operator seat, hydraulic interlocks, the machine is in the correct gear and fuel level. Once you have verified that all of the starting requirements have been met for the machine, then check the wiring on the output circuits of the ECM for the MSS.

Template For The Exciter Coil

Illustration 35	g00783878
If this template was not an original copy that was from a paper copy of Special Instruction, REHS0926, verify that the scale is correct. Measure the diameters of the holes in order to verify the scale.

Template for the ECM

Illustration 36	g00906590