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

Introduction

This Special Instruction provides information for the installation of the 225-0767 Machine Conversion Group . 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 AVSpare service tools.

Required Reference Material

• The Electrical System Schematic for the machine

Note: You can use the Electrical System Schematic to locate the machine harness connectors that are used when you install the Machine Security System.

Parts List

Installation Procedure

Machine Disassembly

Instrument Panel

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Illustration 1	g00751162

1. Open the access door on the right side of the machine. Locate the disconnect switch. Refer to Illustration 1.

2. Turn the disconnect switch to the OFF position.

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

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Illustration 2	g00830660

3. Remove six screws (1) and remove cover panel (2) .

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Illustration 3	g00830661

4. Remove three screws (3) from cover panel (4). Repeat this step for the screws on the other side of the cover panel.

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Illustration 4	g00830662

5. Remove five screws (5). Repeat this step for the screws on the other side of the cover panel.

6. Remove cover panel (4) .

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Illustration 5	g00830664

7. Remove parking brake control knob (7) and the nut.

8. Remove two screws (6) .

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Illustration 6	g00840782

9. Disconnect three electrical connectors (8) from panel assembly (9) .

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Illustration 7	g00830690

10. Disconnect four electrical connectors (10) from panel assembly (9) .

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Illustration 8	g00830692

11. Remove panel assembly (9) .

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Illustration 9	g00831466

12. Remove six screws (11) from panel assembly (12) .

13. Move panel assembly (12) away from the dash in order to allow access to the electrical connectors.

Interior Panel

1. Move the seat forward.

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Illustration 10	g00916656

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Illustration 11	g00916658

2. Remove three screws (14) and two screws (15). Remove interior panel (13) .

Mounting the ECM

1. Connect the 70-pin connector of the 223-3913 Harness Assembly to the MSS ECM.

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Illustration 12	g00916254
Mounting hardware (A) 8T-9655 Mounts (B) 099-3649 Bolts (C) 6I-1418 Spacers (D) 9N-0869 Hard Washer

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Illustration 13	g00916259
(16) Bolt (17) Washer (18) Isolation mounts for the ECM (19) Spacer

2. Place the isolation mounts (18) and spacers (19) on the ECM

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Illustration 14	g00916269

3. Place the ECM on the bosses in the bottom of the compartment.

4. Place a washer over the bolts. Insert the bolts and the washers through the ECM. Tighten the bolts.

   Note: Connect the ground wire from the module to one of the bolts. Tighten the bolt.

Mount the Exciter Coil

Illustration 15	g00909553
Front view of the exciter coil

Illustration 16	g00909554
Front view of the exciter coil and the key switch

Illustration 17	g00916394
(20) Service Connector (21) Key Switch (22) Plug for the LED indicator

1. Remove the nut from the key switch (21). Use a 29 mm (1 1/8 inch) socket.

2. Remove the plate assembly and film for the key switch from the instrument panel. This will expose a notch in the panel for the wiring of the exciter coil.

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Illustration 18	g00918424

3. Place the 213-2323 Plate Assembly in the hole for the key switch.

4. Place the key switch (21) in the hole for the key switch in the panel. Install the exciter coil over the key switch. Route the wires for the exciter coil through the notch that was exposed in the previous step. Place the nut for the key switch over the exciter coil.

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

6. Install the film on the exciter coil. Refer to Illustration 19 for proper placement of the film.

Illustration 19	g00903943

Mounting the LED Indicator

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Illustration 20	g00916394
(20) Service Connector (21) Key Switch (22) Plug for the LED indicator

1. Locate the hole plug for the LED indicator on the instrument panel. Refer to Illustration 20.

2. Remove the hole plug.

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Illustration 21	g00896390

3. Insert the LED indicator in the hole. Ensure that the LED indicator locks in place.

4. Terminate the wires for the indicator light with the 102-8803 Receptacle Kit (3 pin) in the following manner:
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   Table 3

   Contact	Color
   Pin A	Red
   Pin B	Green
   Pin C	Black

5. Install the MSS film (Illustration 22) in a visible location in the cab near the key switch and LED indicator.

Illustration 22	g00808811
MSS Film

Installation of the MSS harness

Illustration 23	g00916695

Use the Electrical System Schematic for the machine to locate the machine harness connectors.

Illustration 24	g00916554

1. Connect the 3-pin receptacle of the LED indicator to the 3-pin plug of the machine harness in the dash

2. Connect the 2-pin receptacle of the exciter coil to the 2-pin plug of the machine harness in the dash.

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Illustration 25	g00916557

3. Connect the 12-pin receptacle of the 223-3913 Harness Assembly to the 12-pin plug of the machine harness in the rear console.

4. Connect wire A275-BK to frame ground.

5. Turn the disconnect switch to the ON position.

Setup of the Machine Security System

Setting the Product Identification Number of the Machine

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

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. Click on the "Connect" icon in the menu bar of the Cat ET in order to establish 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 26	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 27	g00827548

7. Enter the "Product ID" of the machine. The "Product ID" must have 8 digits. The "Product ID" must be formatted as 3 alphanumeric characters and 5 numbers (8 digits). Refer to item 4 in Illustration 28.

Note: The First Quarter of 2001, the AVSpare 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 28.

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Illustration 28	g00860618
(1) AVSpare 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 Cat ET to display the following message.

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Illustration 29	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 Cat ET will display the following message:

Illustration 30	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 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 on 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 following screen.

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Illustration 31	g00827585

6. Press the "Change" button.

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Illustration 32	g00827586

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

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Illustration 33	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. Turn the disconnect switch to the "OFF" position.

6. Reassemble all of the remaining parts and covers.

7. Turn the disconnect switch to the "ON" position.

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

9. 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.

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 exciter coil is not working properly. Check the resistance of the wiring for the exciter coil.

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 are listed below:

• Interlocks in the operator seat

• Hydraulic interlocks

• The machine is in the correct gear

• Fuel level

• AVS data link is functioning correctly

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.