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


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Installation Guide for the Machine Security System on Skid Steer Loaders{7631} [REHS1434]
ELECTRICAL AND STARTING SYSTEM
ELECTRONICS GP-MACHINE
Installation Guide for the Machine Security System on Skid Steer Loaders{7631}
1.1. Introduction
2.1. Required Tools
3.1. Parts List
4.1. Installation Procedure for the Machine Security System ECM and 226-8170 Harness Assembly
5.2. Installation of the MSS ECM
6.2. Installation of the 226-8170 Harness Assembly
7.1. Installation of the LED Indicator
8.1. Installation of the Exciter Coil
9.1. Setup of the Machine Security System (All Machines)
10.2. Setting the Product Identification Number of the Machine
11.2. Set the Time and the Date
12.2. Operational Check (All Models)
13.1. Troubleshooting (All Machines)
14.2. The machine fails to start
15.3. Indicator light does not turn on
16.3. Indicator light remains red
17.3. Indicator light becomes green but the engine will not start
18.1. Template For The Exciter Coil
19.1. Template for the ECM
Skid Steer Loader:
216 (S/N: 4NZ2500-UP)
226 (S/N: 5FZ5200-UP)
228 (S/N: 6BZ700-UP)
236 (S/N: 4YZ4000-UP)
246 (S/N: 5SZ4000-UP)
248 (S/N: 6LZ1000-UP)
252 (S/N: FDG1-UP)
262 (S/N: CED1-UP)

Introduction

This Special Instruction provides information for installation of the 226-8191 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 AVSpare 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     198-5389     Film Ignition    
1     226-8190     Machine Harness Assembly    
1     205-0826     Film (Machine)    
1     225-5927     Film (Warning)    
1     222-3870     Assembly (Ferrite Coil)    
1     202-1292     Bracket    
2     103-2006     Screws    
( 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 for the Machine Security System ECM and 226-8170 Harness Assembly

  1. Raise lift arms and lock into place.

    ------ WARNING! ------

    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 can not make contact with any of the battery posts.

  1. Release the hydraulic system pressure.

    ------ WARNING! ------

    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.

    ----------------------

    Note: Empty the water tank (if equipped) before you tilt the cab.




    Illustration 1g00918779



    Illustration 2g00918780

  1. Remove nut (3) and large washer (4) from the inside of the cab.



    Illustration 3g00918781

  1. Remove bolt (5) and the washer. Repeat for the opposite side of the cab.



    Illustration 4g00918782

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

  1. Raise cab (6) .



    Illustration 5g00918783



    Illustration 6g00563598

  1. Engage cab support lever (7)



    Illustration 7g00918770

  1. Remove the plate (1) that separates the hydraulic compartment and the operator's platform.



    Illustration 8g00918791

  1. Remove the four bolts (8) that secure the right hand support assembly. Refer to Illustration 8.



    Illustration 9g00918792



    Illustration 10g00919107

  1. Push the right hand support assembly to the rear of the machine. Refer to Illustration 9. Move ventilation duct (if equipped) out of the way. Refer to Illustration 10.



    Illustration 11g00918770

  1. Remove the floor plate (2).

Installation of the MSS ECM

The bosses for the ECM may or may not be present on the machine. In some cases the bosses may be present but the bosses are not aligned properly. If the bosses are present and misaligned you must grind off the misaligned bosses and weld on the new bosses to ensure proper alignment.




    Illustration 12g00918808

    (9) Bolt and spacer

    (10) Washer

    (11) Isolation mounts for the ECM

    (12) Boss (if needed)

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

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

    Note: If the bosses are present and aligned properly you will not need the 5C-9855 Bosses . Proceed to Step 8.

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

  1. Tighten the bolts to the bosses.



    Illustration 13g00910937

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



    Illustration 14g00911058

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

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



    Illustration 15g00911074

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



    Illustration 16g00905561

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

Installation of the 226-8170 Harness Assembly




Illustration 17g00921143

MSS harness connections




    Illustration 18g00896395

    222-3870 Assembly (Ferrite Coil)

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



    Illustration 19g00913941

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

  1. Connect the 70-pin connector of the 226-8190 Machine Harness Assembly to the MSS ECM.

  1. Route the 226-8190 Machine Harness Assembly under the hydraulic pump, to the left side of the machine.



    Illustration 20g00921083

  1. Route the portion of the 226-8190 Machine Harness Assembly with the four loose wires to connector 22.

  1. Pull the following wires from connector 22.

    Table 3
    Socket     Wire    
    9     F846-PU    
    10     G848-GN    
    11     T901-PK    
    12     T902-YL    

  1. Secure the four wires to the machine harness.



    Illustration 21g00919235

    Connector 22

  1. Insert the following wires from the 226-8190 Machine Harness Assembly into connector 22.

    Table 4
    Socket     Wire    
    9     F846-PU    
    10     G848-GN    
    11     T901-PK    
    12     T902-YL    

  1. Secure the 226-8190 Machine Harness Assembly from the connector back to the breakout.

  1. Route the service connector to the rear of the machine under the bulkhead into the engine compartment.

  1. Remove the existing service connector from the mounting site. Save the mounting hardware.

  1. Secure the machine's original service connector that was removed in the previous step to the machine harness with the 7K-1181 Cable Straps .

  1. Attach the service connector of the 226-8190 Machine Harness Assembly to the mounting site with the existing hardware.

  1. Use the 7K-1181 Cable Straps to secure the harness back to the breakout.

  1. Route the remaining breakout of the 226-8190 Machine Harness Assembly down to connector 3 at the bottom of the machine under the hydraulic pump.



    Illustration 22g00920833

    Jumper connector

  1. Remove the jumper connector from connector 3. Discard the jumper connector.



    Illustration 23g00920834

  1. Connect the 12-pin connector of the 226-8190 Machine Harness Assembly to connector 3.

  1. Use the 7K-1181 Cable Straps to secure the harness back to the breakout.

  1. Bundle the excess length of the 226-8190 Machine Harness Assembly and lay the bundle in the bottom of the machine.

  1. Use the 7K-1181 Cable Straps to secure the harness back to the MSS ECM.

Installation of the LED Indicator




    Illustration 24g00896390

    LED Indicator

  1. Lay the floor plate in place.

  1. Reinstall the right hand support console and the associated ventilation ducts.



    Illustration 25g00920850



    Illustration 26g00563674

  1. Tilt the cab upward and disengage the support lever.

  1. Lower the cab.



    Illustration 27g00920897

  1. Remove the upper right hand instrument panel.

    Note: You may need to remove the right hand window in order to remove the right hand instrument panel.




    Illustration 28g00920919

    202-1292 Bracket

  1. Install the LED Indicator in the 202-1292 Bracket .



    Illustration 29g00920911

  1. Install the 202-1292 Bracket on the right hand instrument panel with the 103-2006 Screws . The LED indicator is positioned in the lower right hand corner.

  1. Terminate the wires of the LED indicator with the 102-8803 Receptacle Kit (3 pin) . The pin locations are as follows:

    Table 5
    Pin     Wire    
    A     Red Wire    
    B     Black Wire with Green Cover    
    C     Black Wire    



    Illustration 30g00921093

  1. Connect the 3-pin receptacle of the LED indicator to the mating connector of the machine harness.

Installation of the Exciter Coil




    Illustration 31g00920942

  1. Remove the upper left hand instrument panel.

    Note: You may need to remove the left hand window in order to remove the left hand instrument panel.




    Illustration 32g00909553

    Front view of the exciter coil




    Illustration 33g00909554

    Front view of the exciter coil and the key switch

  1. Remove the key switch nut.



    Illustration 34g00783001

  1. Install the paper template over the key switch.

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

  1. Replace the key switch nut. Hand tighten.

  1. Mark the drill site with a center punch. Refer to Illustration 34.

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

  1. 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.

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

  1. 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 35.



    Illustration 35g00920946

  1. Install the film on the exciter coil.

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

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



    Illustration 36g00920947

  1. Connect the 2-pin receptacle of the exciter coil to the mating connectors of the machine harness.

    ------ WARNING! ------

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

  1. Install the MSS film in a visible position in the cab as close as possible to the key switch. Refer to Illustration 35



Illustration 37g00808811

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.

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

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

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



    Illustration 38g00827547

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

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



    Illustration 39g00827548

  1. Enter the "Product ID" of the machine. Refer to Illustration 40 for the proper format of the Product Identification Number.

    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 40.




    Illustration 40g00860618

    (1) AVSpare'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.

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



    Illustration 41g00827549

  1. 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 42g00827550

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.

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

  1. Start the ET.

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

  1. 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.



    Illustration 43g00827585

  1. Press the "Change" button.



    Illustration 44g00827586

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



    Illustration 45g00827587

  1. 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.

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

Operational Check (All Models)

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

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

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

  1. Turn the key to the OFF position.

  1. Disconnect the grounded battery cable from the battery.

  1. Reassemble all of the remaining parts and covers.

  1. 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.

  1. Attach the Machine Security System film on the door of the machine or on the ROPS near the mount or dismount route of the operator.

  1. 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 46g00783878

If this template was not an original copy that was from a paper copy of Special Instruction, REHS1434, verify that the scale is correct. Measure the diameters of the holes in order to verify the scale.

Template for the ECM




Illustration 47g00906590

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