Installation Instructions for the Machine Security System on the Small Wheel Loaders{7631} Caterpillar

Integrated Toolcarrier:

IT14G (S/N: 8ZM1-UP; 1WN1-UP)

IT28G (S/N: 8CR1-UP; 9AR1-UP)

Wheel Loader:

914G (S/N: 7ZM1-UP; 9WM1-UP)

924G (S/N: AAN1-UP; 9SW1-UP; 3PZ1-UP)

924GZ (S/N: AAB1-UP; 6YW1-UP; 3DZ1-UP)

928G (S/N: 6XR1-UP; 7SR1-UP)

Introduction

This Special Instruction provides information for installation of the 227-0902 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.

Table 1

Part Number	Description
	Drill Gp 12.7 mm (0.5 inch)
1U-5893	Drill Bit Set (135 Degree Split Point)
9S-1748	Socket Wrench Set (1/2 Inch Drive)
199-6156	Socket Wrench Set (1/2 Inch Drive-Metric)
194-3584	Socket Wrench Set (Torx)
1U-7230	Hand Tool Gp (Screwdrivers)
8T-9293	Torque Wrench (1/2 inch Drive)
1U-7123	Adapter
190-8900	Connector Repair Kit
	.5 inch to 1.0 inch Universal Drill Bit
	Center Punch

Parts List

Table 2

Contents of the Retrofit Kit for the Machine Security System All parts are contained in the 226-8191 Machine Conversion Group . (1)
Quantity	Part Number	Description
3	6I-1418	Spacers
15	7K-1181	Cable Straps
3	5C-9855	Boss
3	099-3649	Bolt
3	9N-0869	Hard Washers
1	102-8802	Receptacle Kit
1	102-8803	Receptacle Kit
2	151-6320	Removal Tool
6	8T-9655	Isolation Mount
1	165-5655	Lamp
1	207-5262	Machine Security System Electronic Control Module (2)
1	205-8257	Coil
1	227-0901	Machine Harness Assembly
1	198-5389	Film (Ignition)
1	205-0826	Film (Machine)
1	222-3870	Assembly (Ferrite Coil)
1	155-2260	Plug Kit
1	155-2270	Plug Kit
1	225-5927	Film (Security Notice)

( 1 )	This kit contains parts that are not used in with all applications. Discard any unused parts.
( 2 )	This includes two 206-5162 Electronic Keys .

Installation Procedure

Machine Disassembly

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Illustration 1	g00448370

1. Open the access cover on the left side of the machine. Locate the disconnect switch. Refer to Illustration 1.

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Illustration 2	g00101715

2. Turn the disconnect switch to the OFF position.

Note: Put identification marks on all wires and connectors for installation purposes.

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Illustration 3	g00923667

3. Remove 7 screws.

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Illustration 4	g00923671

4. Remove dash assembly (1) .

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Illustration 5	g00923335

5. Remove two screws (3) in order to remove cover (2) .

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Illustration 6	g00923342

6. Raise storage cover (4) on the storage component.

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Illustration 7	g00923345

7. Remove three screws (5). Remove storage compartment.

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Illustration 8	g00923349

8. Remove rubber cover (6) .

9. Pull down liner (7) and remove the liner.

Mounting the LED Indicator

Illustration 9	g00896390

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Illustration 10	g00923744

1. Drill a 13 mm (1/2 inch) hole for mounting of the LED indicator through the dash. Refer to Illustration 10.

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Illustration 11	g00923765

2. Install the LED indicator into the hole you made in the previous step. Ensure that the indicator lamp locks in place. Refer to Illustration 11.

3. Terminate the wires of the indicator lamp with a 3-pin receptacle. The following table lists the location of the pins:
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   Table 3

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

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Illustration 12	g00808811

4. Install the MSS film in a visible location in the cab near the key start switch and the LED indicator.

Mounting the Exciter Coil

Illustration 13	g00909553
Front View of the exciter coil

Illustration 14	g00909554
Front view of the exciter coil and key switch

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Illustration 15	g00924569

1. Remove the nut (1) from the key switch. Use a 29 mm (1 1/8 inch) socket.

2. Remove the two nuts from the back of plate (2). Remove the plate (2) from the instrument panel.

3. Remove the film from the plate (2) .

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Illustration 16	g00924577

4. Cut a notch in the dash for wiring of the exciter coil.

5. Reinstall the plate (2) and tighten the two nuts.

6. Place the key switch in the hole for the key switch in the dash. Install the exciter coil over the key switch. Route the wires for the exciter coil through the notch that was made in the previous step. Place the nut for the key switch over the exciter coil.

7. Tighten the nut to a torque of 13.6 ± 4 N·m (10 ± 3 lb ft).

8. Terminate the wires of the exciter coil with the 102-8802 Receptacle Kit (2 pin). The location of the connector pins does not matter.

9. Install the 198-5389 Film on the exciter coil. Refer to Illustration 17 for proper placement of the film.

Illustration 17	g00903943

Mounting the ECM

Note: Some machine will have preexisting bosses. If this is the case with your machine, proceed to step 9.

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Illustration 18	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.

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

2. Tighten the bolts to the bosses.

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Illustration 19	g00924610

3. Prepare the rear wall of the cab for welding by removing enough foam to allow the 5C-9855 Bosses to be welded to the rear wall.

4. Remove any paint from surface of the area to be welded.

5. Tack weld the bosses to the rear wall of the cab while the bosses are installed on the MSS ECM.

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

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Illustration 20	g00929486

7. Place the ECM on the liner and cut the insulation around the ECM. Refer to Illustration 20.

8. Remove the insulation from the liner.

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Illustration 21	g00924624

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

Mounting the Ferrite Coil

Illustration 22	g00896395
222-3870 Assembly (Ferrite Coil)

1. Connect the 222-3870 Assembly (Ferrite Coil) to the 2 pin connectors of the 227-0901 Machine Harness Assembly .

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Illustration 23	g00913941

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

Installation of the 227-0901 Machine Harness Assembly

Illustration 24	g00924629

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Illustration 25	g00926112

1. Route the 227-0901 Machine Harness Assembly through the bulkhead into the compartment for the fuse panel and relays.

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Illustration 26	g00926116
Compartment for the fuse panel and relays

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Illustration 27	g00926117
Bottom of machine

2. Route the 227-0901 Machine Harness Assembly out the bottom of the compartment for the fuse panel and relays.

   Note: You may remove the ladder from the side of the machine in order to ease the difficulty of the installation of the 227-0901 Machine Harness Assembly .

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Illustration 28	g00926247

3. Route the 227-0901 Machine Harness Assembly along the bottom of the machines cab and up through the floor of the cab into the dash.

4. Connect the 70-pin connector of the 227-0901 Machine Harness Assembly to the MSS ECM.

1. Use the 7K-1181 Cable Straps to secure the 227-0901 Machine Harness Assembly to the machine.

2. Disassemble the fuse panel to allow access to the main power relay.

3. Disconnect the machine harness from the main power relay.

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Illustration 29	g00926248

4. In the compartment for the fuse panel and relays make the following connections of the 227-0901 Machine Harness Assembly that are listed below:
   • Connect receptacle A-C11 of the 227-0901 Machine Harness Assembly to the plug of the main power relay.

   • Connect plug A-C7 of the 227-0901 Machine Harness Assembly to the receptacle of the machine harness for the main power relay.

   • Connect terminal A-T1 of the 227-0901 Machine Harness Assembly to the battery side of the main power relay (wire 117-RD).

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Illustration 30	g00926848

5. Make the following under the cab connections of the 227-0901 Machine Harness Assembly that are listed below:
   • Remove pin 11 (403-GN) from connector 10 of the machine harness

   • Insert pin 11 (403-GN) from connector 10 into pin 1 of connector A-C8 of the 227-0901 Machine Harness Assembly .

   • Insert terminal A-T2 (403-GN) of the 227-0901 Machine Harness Assembly into the slot for pin 11 of connector 10.

   • Disconnect connector 11 of the machine harness.

   • Connect plug A-C3 of the 227-0901 Machine Harness Assembly to the receptacle of connector 11.

   • Connect receptacle A-C6 of the 227-0901 Machine Harness Assembly to the plug of connector 11.

   • Connect plug A-C5 227-0901 Machine Harness Assembly to the receptacle A-C8 of the 227-0901 Machine Harness Assembly .

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Illustration 31	g00926876

6. Connections for the service connectors of the 227-0901 Machine Harness Assembly are listed below:
   • Remove the existing service connector from (connector 34) from the mounting site. Save the hardware.

   • Connect connector A-C2 of the 227-0901 Machine Harness Assembly to connector 34 of the machine harness.

   • Mount connector A-C4 of the 227-0901 Machine Harness Assembly to the mounting position of for the service connector with the existing hardware.

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Illustration 32	g00927593
Mounted Service Connector

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Illustration 33	g00927387

7. Terminate the wires of 227-0901 Machine Harness Assembly that were routed to the dash to the 155-2260 Connecting Plug Kit and 155-2270 Connecting Plug Kit . Refer to the Tables that are listed below:
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   Table 4

   155-2260 Connecting Plug Kit
   Pin	Wire	Label
   A	F846-PU	A-T3
   B	G848-GN	A-T4
   C	210-BK	A-T5

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   Table 5

   155-2270 Connecting Plug Kit
   Pin	Wire	Label
   1	T901-YL	A-T6
   2	T902-PK	A-T7

8. Connect the plug for the LED indicator to the Receptacle for the LED indicator.

9. Connect the plug for the exciter coil to the receptacle for the exciter coil.

10. Use the 7K-1181 Cable Straps to secure the 227-0901 Machine Harness Assembly back to the MSS ECM.

Setup of the Machine Security System

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.

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Illustration 34	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.

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Illustration 35	g00827548

7. Enter the "Product ID" of the machine. Refer to Illustration 36 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 36.

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Illustration 36	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.

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Illustration 37	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 38	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.

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Illustration 39	g00827585

6. Press the "Change" button.

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Illustration 40	g00827586

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

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Illustration 41	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" ".

Operational Check

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. Reconnect the grounded battery cable to the battery.

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

9. Attach the 225-5927 Film (Security Notice) on the door of the machine or on the ROPS near the mounting and dismounting location of the operator.

Troubleshooting

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.