Installation of the Machine Security System (MSS) Universal Attachment Kit {7631, 7631} Caterpillar

Caterpillar Products

All Machines

Introduction

This Special Instruction provides information for installation of the 237-5920 Service 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.

The MSS Universal Attachment Kit is intended for use on all products (Caterpillar or other manufacturer) that are without the MSS Custom Kit.

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.

Note: The Advanced Machine Security System is a Software Enabled Attachment (SEA). To add this attachment, the "Advanced Machine Security" status must be "Installed" in the ECM configuration (Caterpillar Electronic Technician (Cat^® ET) and factory password required).

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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
151-0968	Cordless Drill Gp (12 V, 3/8 inch, Variable Speed)
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 (DT)
-	1 5/16 inch Hole Saw
-	13 mm (1/2 inch) to 25 mm (1 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 237-5920 Service Kit.(1)
Quantity	Part Number	Description
2	3E-5239	Relay Assembly
1	225-8513	Harness Assembly (Wiring)
4	129-3178	Locknut
6	8T-9655	Mount
3	6I-1418	Spacer
20	7K-1181	Cable Strap
3	6V-9189	Locknut
3	200-6260	Button Head Screw
2	115-1615	Relay
1	102-8802	Receptacle Kit
1	102-8803	Receptacle Kit
2	115-8109	Splice
2	151-6320	Tool (Removal)
1	165-5655	Lamp (Red) (Green)
2	184-0982	Screw (Pan Head)
1	213-2323	Plate Assembly
1	222-3870	Coil (Ferrite)
1	225-5927	Film (Security)
1	205-0826	Film (Machine)
1	198-5389	Film (Exciter Coil)
1	200-5125	Film (Exciter Coil)
1	205-8257	Coil Assembly (Exciter)
1	226-5602	Film (Exciter Coil)
1	224-3385	Film (Exciter Coil)
1	207-5262	Control Group (MSS ECM) (2)
4	141-4976	Screw
6	9N-0869	Hard Washer
1	149-9818	Plate (Service Connector)
1	230-8173	Plate (ECM Cover)

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

Alternate Parts That May Be Needed

For Caterpillar machines that use the current standard 5P-8500 Key, the existing switch can be reused with the MSS Universal Kit. For early Caterpillar machines (either without a keyswitch or using a different key) and for competitive non-Cat machines, a new key switch will be needed. Table 3 lists the recommended Caterpillar part options for replacement key switches.

Table 3

Replacement Key Switches
Machine Type	Replacement Key Switch Type
	3-Position (Off-On-Start) 10 Amp @ 24 VDC(1)	4-Position (Off-Accessory-On-Start) 5 Amp @ 24 VDC, 10 Amp @ 12 VDC(1)	5-Position (Preheat-Off-Accessory-On-Start) 10 Amp @ 24 VDC(1)
Current Cat Machines Using 5P-8500 Key	Not Needed	Not Needed	Not Needed
Older Cat Machines with No Keyswitch	9G-7641 Start Switch Gp	110-7883 Start Switch Gp	7Y-3918 Heat Start Switch Gp
Non-Cat Machines	9G-7641 Start Switch Gp	110-7883 Start Switch Gp	7Y-3918 Heat Start Switch Gp

(1)	Make sure that the current ratings for the key switch selected meet or exceed the maximum current level needed by the machine.

Pre-installation Survey of the Machine

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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. Check for space around the key switch to mount the exciter coil. If there is no room to mount the exciter coil, then assess how you can move the key switch to an alternate location. This location should allow you to mount the exciter coil and still allow the operator to insert and turn the key. The 213-2323 Plate Assembly will aid in mounting the key switch if an alternate location is necessary.

2. Check for a location to mount the 207-5262 Electronic Control Module (Machine Security System)

   • Locate the ECM nearby the key switch so that the harness, when routed between the ECM and the key switch, does not require alterations.

   • Also select a location that is not obvious to a thief, but accessible for the service person.

   • The ECM has specific hardware to make the unit hard to access and remove. Be sure to use all supplied nuts, bolts, and security plates.

   • DO NOT alter the length of the wiring between the MSS ECM and the exciter coil. If this length is altered, the system will not be compliant with FCC requirements, and may not operate properly.

   • DO NOT install the MSS ECM or the relays in engine compartments or other high-heat locations. Doing so may result in early device failure and void the warranty.

   • DO NOT locate the MSS ECM in the battery box. The relays on the MSS ECM may ignite the battery gases causing an explosion.

   • DO NOT install the ECM anywhere in the machine where submersion in water is likely to occur. If the MSS ECM is submersed in water, the machine may not start.

Disassembly of the Machine

1. Use the proper safety procedures to secure the machine during installation of the Machine Security System.

2. Turn off the power to machine using the battery disconnect switch or disconnect the terminals from the batteries

3. Remove any panels and components to gain access to:

   • The area around the key switch

   • The mounting area for the ECM

   • Wiring for the main relay

   • Wiring for the start relay

   • The routing path for the MSS wiring harness

Mounting the ECM

Illustration 1	g06096585
MSS ECM - Exploded view (1) 200-6260 Button Head Screw (2) 9N-0869 Hard Washer (3) 230-8173 Plate (Cover) (4) 184-0982 Button Head Screw (5) 3E-5239 Relay Assembly or 115-1615 Relay Assembly (6) 129-3128 Locknuts (7) 225-8513 Harness Assembly (8) 222-3870 Coil (Ferrite) (9) 8T-9655 Mount (10) 6I-1418 Spacer (11) 207-5262 Electronic Control Module (MSS) (12) 6V-9189 Locknuts

1. Use the ECM template to lay out and mark the ECM mounting area. Refer to Illustration 30.

2. Center punch the three mounting holes.

3. Drill the three holes with a 10 mm (3/8 inch) drill bit.
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   Illustration 2	g06096597
   Ferrite coil attached to harness ( 7K-1181 Cable Strap).

4. Attach the two 2-pin connectors of the 222-3870 Ferrite Coil Assembly to the 225-8513 Harness Assembly. Refer to Illustration 2.

5. Select the two relays that match the battery voltage of the machine and connect to the 225-8513 Harness Assembly
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   Table 4

   Voltage	Relay
   24 VDC	3E-5239
   12 VDC	115-1615

6. Attach the relays to the 230-8173 Security Cover as shown with the 184-0982 Button Head Screws and the 129-3178 Locknut.

7. Attach 225-8513 Harness Assembly to ECM.

8. Install 200-6260 Screws from the back of the mounting location that you selected previously.

9. Install the 8T-9655 Mounts isolation mounts and 6I-1418 Spacers to the ECM.

10. Mount ECM in the selected location.

11. Mount 230-8173 Security Plate over the ECM using 6V-9189 Locknuts, with 225-8513 Harness Assembly exiting the top of the security plate.

Routing of the 225-8513 Harness Assembly

1. Route the exciter coil/key switch portion of 225-8513 Harness Assembly to the location of the key switch of the machine. The following list contains the exciter coil/key switch portion of 225-8513 Harness Assembly:

   • 200BK wire

   • 308YL wire

   • 306GN wire

   • 105RD wire

   • One Two-pin connector

   • One Three-pin connector

2. Route the service connector portion of 225-8513 Harness Assembly (two nine-pin connectors) to the existing location of the service connector.

   Note: If there is no port for the service connector on the machine, then you have two options:

   • Route the harness to a panel on the machine and mount the new service connector to that panel.

   • Bundle the harness at the ECM and secure harness with a 7K-1181 Cable Strap. Ensure that the service connector is exposed for access during routine servicing of the Machine Security System.

3. Route the 308-YL(Yellow)wires to the connection point for the main relay of the machine.

4. Route the 306-GN(Green)wires to the connection point for the start relay of the machine.

Mounting the Exciter Coil in the Original Key Switch Location

This procedure is performed only if there is adequate room to mount the exciter coil at the original location of the key switch. Refer to Illustration 29.

1. Remove the key switch.

2. Apply the template for the exciter coil with the tab at the 12 O'CLOCK position.
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   Illustration 3	g00913058
   Typical Example

3. Mark the hole with a center punch.

4. Use a 10 mm (3/8 inch) drill bit to drill out the hole.

Mounting the Key Switch and the Exciter Coil in an Alternate Location

This procedure is performed only if there is inadequate space to mount the exciter coil at the original location of the key switch and the key switch must be relocated to an alternate position. Refer to Illustration 28.

1. Use the template for the exciter coil (alternate location) to lay out alternate mounting location with locating tab at the 12 O'CLOCK position,

2. Mark all four holes with a center punch.
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   Illustration 4	g00999589

3. Drill out the left-hand hole with 25.8 mm (1 inch) drill bit.
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   Illustration 5	g00999594

4. Drill out top and bottom hole with 6.6 mm (1/4 inch) drill.
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   Illustration 6	g00999598

5. Drill out the right-hand hole with a 13.4 mm (1/2 inch) drill.
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   Illustration 7	g00999600

6. Mount 213-2323 Plate with 129-3178 Locknuts.

Key switch Termination

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Illustration 8	g06096635
Key Switch termination schematic

1. Attach the wires of the 225-8513 Harness Assembly to the key switch as listed below:
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   Table 5

   Terminal	Wire
   "B" (unswitched power)	105-RD(Red)
   "R" (switched power)	308-YL(Yellow)
   "S" (start circuit)	306-GN(Green)

   Note: If the key switch does not have screw terminals, then cut off the ring terminals and splice the wires of the 225-8513 Harness Assembly to the key switch wires using approved termination components.

2. Find a ground stud near the key switch and attach the 200-BK(Black)wire to the ground stud. If no stud is available, then cutoff the terminal and splice to a ground wire in one of the machine harnesses using approved termination components.
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   Illustration 9	g00909553
   205-8257 Exciter Coil

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   Illustration 10	g00999604
   Typical installation of the key switch and the 205-8257 Exciter Coil

3. Remount the key switch and the 205-8257 Exciter Coil.

4. Install 102-8802 Receptacle Kit (2 Pin) to the wires of the 205-8257 Exciter Coil.

   Note: Polarity is not important in Step 4.

5. Attach the 2-pin receptacle of 205-8257 Exciter Coil to 2-pin plug on 225-8513 Harness Assembly.

6. Insert the key into the key switch and turn the key switch to the OFF position.

7. Apply the proper key switch film to the exciter coil with the film properly aligned. Refer to Table 6.
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   Table 6

   Film	Positions	Orientation
   200-5125	"PREHEAT-OFF-ON-START"	OFF at 12 o'clock
   198-5389	"OFF-ON-START"	OFF at 12 o'clock
   224-3385	"OFF-ON-START"	ON at 12 o'clock
   226-5602	"OFF-ACC-ON-START"	ON at 12 o'clock

LED Mounting

1. Drill a 13 mm (1/2 inch) hole in the dash near the exciter coil.

   Note: When selecting a location for the hole, ensure that there is sufficient clearance behind the dash to accommodate the LED and the LED wires. When drilling the hole, ensure that there are no wires behind the dash that will be damaged by the drilling.

2. Install 173-1201 Film (with bottom cutout) centered over the hole from Step 1.
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   Illustration 11	g00896390

3. Install the 165-5655 Lamp As in the hole.

4. Terminate the wires of the 165-5655 Lamp As with 102-8803 Receptacle Kit as listed in Table 7.
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   Table 7

   Pin	Wire
   A	Red
   B	Green
   C	Black

5. Attach the 3-pin receptacle of 165-5655 Lamp As to the 3-pin plug on 225-8513 Harness Assembly.

Terminating Relay Circuits

Illustration 12	g06096644
Example of a connection of the MSS start relay for a start circuit controlled by an ECM

Note: When an ECM controls the Crank or Start relay via a key switch input, you will need to configure the MSS start relay to control the key switch input instead of the start or crank relay. This will prevent the control from logging and warning the operator of the event. Illustration 12 is an example of a connection of the MSS start relay for a start circuit controlled by an ECM.

1. Locate the connector in the machine harness that contains the wiring for the main relay.

   • If the connector has pins (sockets) that are the same as the pins on the 225-8513 Harness Assembly, then extract the machine harness pin (socket) and replace with the socket (wire 308-YL(Yellow)) from the 225-8513 Harness Assembly. Take the free pin (socket) from the machine harness, and with the 115-8109 Splice, connect to the 308-YL(Yellow)socket (pin) on the 225-8513 Harness Assembly.

   • If the pins (sockets) are not the same size, then cut off the pin and socket on the 225-8513 Harness Assembly then cut the wire for the main relay on the machine harness and splice with approved termination components.

2. Locate the connector in the machine harness that contains the wiring for the start relay.

   • If the connector has pins (sockets) that are the same as the pins on the 225-8513 Harness Assembly, then extract the machine harness pin (socket) and replace with the socket (wire 306-GN(Green)) from the 225-8513 Harness Assembly. Take the free pin (socket) from the machine harness, and with the 115-8109 Splice, connect to the 306-GN(Green)socket (pin) on the 225-8513 Harness Assembly.

   • If the pins (sockets) are not the same size, then cut off the pin and socket on the 225-8513 Harness Assembly then cut the wire for the main relay on the machine harness and splice with approved termination components.

Installation of J1939 Jumper to the Service Connector

Caterpillar machines that utilize J1939 communications require the installation of two wire twisted-pair jumper to ensure that Cat^® Electronic Technician (Cat ET) service tool will be able to communicate with all ECM installed on the machine.

Illustration 13	g06096649

Refer to Illustration 13 to determine, if the two wire jumper is required. If the machines service connector is configured as shown in the Illustration 13, use the information provided to install the jumper in the 225-8513 Harness Assembly.

Two Wire Twisted-Pair Jumper installation

1. Locate connectors A-C2 and A-C3 on the 255-8513 Harness Assembly.

2. Insert twisted-pair jumper between contacts F and G of both connectors.

   Note: Ensure that contact F on A-C2 is connected to contact F on A-C3 and contact G on A-C2 is connected to contact G on A-C3. If these connections are inadvertently crossed the machine, J1939 communications will be disrupted, causing machine operational issues.

Illustration 14	g06096656

Service Connector Mounting (Machine with Existing Service Connector)

Illustration 15	g01011825
Service Connector Mounting Template

1. Remove the current service connector from the mounting hole

2. Connect the machine service connector to the mating connector of the 225-8513 Harness Assembly.

3. Install the new service connector using the existing hardware, or the 149-9818 Plate and the 141-4976 Screws.

Service Connector Mounting (Machine without Service Connector)

If the MSS ECM is accessible during routine maintenance, you can secure the service connector to the harness near the ECM, or you can mount the service connector on a panel that is easily accessible.

To mount the service connector to a panel:

1. Use 149-9818 Plate as a template to lay out the five holes.

2. Mark the holes with a center-punch.

3. Drill out the large center hole with a 33.5 mm (1 5/16 inch) hole saw.

4. Use a 2.3 mm (3/32 inch) drill bit to drill the four perimeter holes.
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   Illustration 16	g01007390
   Service connector (10) Panel (11) Service Connector (12) 141-4976 Screws (13) 149-9818 Plate

5. Install the new service connector using the 149-9818 Plate and the 141-4976 Screws.

Setup of the Machine Security System

Setting the Product Identification Number of the Machine

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

1. Turn the battery disconnect switch to the ON position or reconnect the battery cables to the battery.

2. Connect the Cat ET to the service connector via the communication adapter.

3. Place the "Master Access Level" key into the key start switch and turn the key to the ON position.

4. Start the Cat ET and click the "Connect" icon in the menu bar to start communications.

5. Select the "Configuration" option from the "Service" Menu. This will display the "Configuration" screen.
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   Illustration 17	g06096662

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

7. Click the "Change" button that is on the "Configuration" screen. This will display a dialog box.
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   Illustration 18	g06096672

8. Enter the "Product ID" of the machine. Refer to Illustration 19 for the proper format of the Product Identification Number.

   Note: In the First Quarter of 2001, the Product Identification Number (PIN) of Caterpillar changed from 8 characters to 17 characters. The "Product ID" that is required by the Machine Security System is Item (4) in Illustration 19.

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   Illustration 19	g00782940
   (1) Caterpillar's World Manufacturing Code (characters 1 - 3). (2) Machine descriptor (characters 4 - 8) ( 3) Check (character 9) ( 4) Machine Indicator Section (MIS) or Product Sequence Number (characters 10 - 17). These characters were previously referred to as the Serial Number.

9. Click the "OK" button. This selection will cause the Cat ET to display the following message.
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   Illustration 20	g00827549

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

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

Illustration 21	g00827550

Setting the Time, Date, and Time Zone

Set the correct time, date, and time zone for the Machine Security System. Use the following procedure to set the time and the date.

Note: Changing the clock requires a "Master Access Level" key or a factory password. When using a "Master Access Level" key, ensure that the MSS is not in the 30 second grace period before inserting the key. To determine if MSS is in the 30 second grace period, view the "MSS Status" LED. When the 30 second grace period is active, the "MSS Status" LED will be illuminated GREEN with the key switch in the OFF position.

1. Connect the Cat 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 Cat ET.

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

5. Once the Cat ET has established communications with the MSS ECM, select the "ECM Date/Time" option from the "Service" menu. This will cause the Cat ET to display the "ECM Date/Time" screen.
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   Illustration 22	g00997474

6. Press the "Change" button. This will cause the "Date/Time" dialog box to appear.
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   Illustration 23	g00997476

7. Select the local time zone from the drop-down menu.
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   Illustration 24	g00997478

8. Enter the local date and time. Use an accurate source for the time.

   Note: Clocks of laptop computer are not accurate. The computer may have a different time than the local time.

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   Illustration 25	g00997479

9. Then press the "OK" button. The Cat ET will display the following message.
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   Illustration 26	g00997480

10. Click the "Yes" button to change the date and time or click the "No" button to cancel the change. The Cat ET will display the new time on a 24-hour clock.
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    Illustration 27	g00997483

11. 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 illuminates.

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

4. Turn the key to the OFF position.

5. Turn the disconnect switch to the OFF position.

6. Secure 225-8513 Harness Assembly to the machine with the 7K-1181 Cable Straps

7. Reassemble all the remaining parts and covers.

8. Turn the disconnect switch to the ON position.

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

10. Attach the "Machine Security System" film on the door of the machine or on the ROPS near the "mount and dismount" location of the operator.

Key Switch Templates

Illustration 28	g01005768
Use this template when relocating the key switch

Illustration 29	g01005919
Use this template when key switch stays in present location.

ECM Template

Illustration 30	g00906590

Schematics

Illustration 31	g06391489

Illustration 32	g06391495

Illustration 33	g06391499

Illustration 34	g06391502