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


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Installation Instructions for the Machine Security System on the Medium Wheel Loaders{7631} [REHS1441]
ELECTRICAL AND STARTING SYSTEM
ELECTRONICS GP-MACHINE
Installation Instructions for the Machine Security System on the Medium Wheel Loaders{7631}
1.1. Introduction
2.1. Required Tools
3.1. Parts List
4.1. Installation Procedure
5.2. Machine Disassembly
6.2. Mounting the LED Indicator
7.2. Mounting the Exciter Coil
8.2. Mounting the ECM
9.2. Mounting the Ferrite Coil
10.2. Installation of the 228-1841 Machine Harness Assembly
11.2. Mounting the Service Connector
12.1. Setup of the Machine Security System
13.2. Setting the Product Identification Number of the Machine
14.2. Set the Time and the Date
15.2. Operational Check
16.1. Troubleshooting
17.2. The machine fails to start
18.3. Indicator light does not turn on
19.3. Indicator light remains red
20.3. Indicator light becomes green but the engine will not start
Integrated Toolcarrier:
IT38G (S/N: 7BS1-UP; 1CW1-UP)
Wheel Loader:
938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)

Introduction

This Special Instruction provides information for installation of the 228-1842 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 228-1842 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    
1     115-8109     Splice    
4     141-4976     Screw (Washer Head)    
1     149-9818     Plate    
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     228-1841     Machine Harness Assembly    
1     198-5389     Film (Ignition)    
1     205-0826     Film (Machine)    
1     222-3870     Assembly (Ferrite Coil)    
1     155-2270     Plug Kit    
1     155-2260     Plug Kit    
1     213-2323     Plate    
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




    Illustration 1g00448370

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



    Illustration 2g00111693

  1. Turn the disconnect switch to the OFF position.

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




    Illustration 3g00923667

  1. Remove 7 screws.



    Illustration 4g00923671

  1. Remove dash assembly (1) .



    Illustration 5g00923335

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



    Illustration 6g00923342

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



    Illustration 7g00923345

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



    Illustration 8g00923349

  1. Remove rubber cover (6) .

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

Mounting the LED Indicator




Illustration 9g00896390



    Illustration 10g00923744

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



    Illustration 11g00923765

  1. 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.

  1. Terminate the wires of the indicator lamp with the 102-8803 Receptacle Kit (3-pin). The following table lists the location of the pins:

    Table 3
    Location     Wire    
    Pin A     Red Wire    
    Pin B     Black Wire with Green Cover    
    Pin C     Black Wire    



    Illustration 12g00929699

  1. 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 13g00929701

Front View of the exciter coil




Illustration 14g00929703

Front view of the exciter coil and key switch

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

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



    Illustration 15g00924577

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



    Illustration 16g00918424

    213-2323 Plate

  1. Install the 213-2323 Plate over the hole for the key switch and tighten the two nuts.

  1. 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.

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

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

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



Illustration 17g00929706

Mounting the ECM

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




    Illustration 18g00910917

    (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.

  1. Tighten the bolts to the bosses.



    Illustration 19g00924610

  1. 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.

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

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

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



    Illustration 20g00929735

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

  1. Remove the insulation from the liner.



    Illustration 21g00924624

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

Mounting the Ferrite Coil




Illustration 22g00929710

222-3870 Assembly (Ferrite Coil)

  1. Connect the 222-3870 Assembly (Ferrite Coil) to the 2 pin connectors of the 228-1841 Machine Harness Assembly .



    Illustration 23g00929711

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

Installation of the 228-1841 Machine Harness Assembly




Illustration 24g00929723

  1. Route the 228-1841 Machine Harness Assembly through the bulkhead into the compartment for the fuse panel and relays.



    Illustration 25g00926116

    Compartment for the fuse panel and relays




    Illustration 26g00926117

    Bottom of machine

  1. Route the 228-1841 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 228-1841 Machine Harness Assembly .




    Illustration 27g00931568

  1. Route the 228-1841 Machine Harness Assembly along the bottom of the machines cab and up through the floor of the cab into the dash.

  1. Connect the 70-pin connector of the 228-1841 Machine Harness Assembly to the MSS ECM.

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

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



    Illustration 28g00930046

  1. In the compartment for the fuse panel and relays make the following connections of the 228-1841 Machine Harness Assembly that are listed below:

    • Connect receptacle A-C3 of the 228-1841 Machine Harness Assembly to the plug of the main power relay.

    • Connect plug A-C7 of the 228-1841 Machine Harness Assembly to the receptacle of the machine harness for the main power relay.

    • Connect terminal A-T1 of the 228-1841 Machine Harness Assembly to the battery side of the main power relay (wire 117-RD).




    Illustration 29g00930066

  1. Make the following under the cab connections of the 228-1841 Machine Harness Assembly that are listed below:

    • Disconnect the 8 pin connector of the shift lever.

    • Remove pin 5 (wire 306-GN) from the 8 pin connector of the shift lever.

    • Insert A-T10 (wire A346-BU) into slot 5 of the 8-pin connector of the shift lever.

    • Insert contact 5 (wire 306-GN) and A-T8 (wire 306-GN) into the 115- 8109 Splice .

    • Reconnect the 8-pin connector of the shift lever.




    Illustration 30g00930071

  1. Pull the blade connector (wire 403-GN) off the service meter, insert the male blade (A-T2) (wire 403-GN) of the MSS harness to this wire and secure with electrical tape. Then take the female blade ( A-T9 ) (wire 403-GN) on the MSS harness and insert on the service meter.



    Illustration 31g00930247

  1. Connections for the service connectors of the 228-1841 Machine Harness Assembly are listed below:

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

    • Connect connector A-C2 of the 228-1841 Machine Harness Assembly to the service connector of the machine harness.

    • Mount connector A-C4 of the 228-1841 Machine Harness Assembly to the mounting position of for the service connector with the existing hardware.

    Note: On some machine the service connector in not mounted. If this is the case, refer to the ""Mounting the Service Connector" " section of this manual.




    Illustration 32g00927593

    Mounted Service Connector




    Illustration 33g00927387

  1. Terminate the wires of 228-1841 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:

    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    

    Table 5
    155-2270 Connecting Plug Kit    
    Pin     Wire     Label    
    1     T901-YL     A-T6    
    2     T902-PK     A-T7    

  1. Connect the plug for the LED indicator to the receptacle for the LED indicator.

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

  1. Use the 7K-1181 Cable Straps to secure the 228-1841 Machine Harness Assembly back to the MSS ECM.

Mounting the Service Connector

Use the procedure that is listed below only if there is not a preexisting mount for the service connector.




    Illustration 34g00927610

  1. Use a hole saw to drill a 35 mm (1 3/8 inch) hole in front plate of the left hand console.

    Note: Check for any obstructions in the path of the drill prior to drilling.




    Illustration 35g00930079

    (12) Console

    (13) Service Connector

    (14) 141-4976 Washer Head Screws

    (15) 149-9818 Plate

  1. Use the service connector as a template. Mark the location of the mounting screws.

  1. Drill four 3 mm (1/8 inch) holes. These holes will be used to mount the service connector.

  1. Mount the service connector.



Illustration 36g00927593

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.

  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 37g00827547

  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 38g00827548

  1. Enter the "Product ID" of the machine. Refer to Illustration 39 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 39.




    Illustration 39g00860618

    (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 40g00827549

  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 41g00827550

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 42g00827585

  1. Press the "Change" button.



    Illustration 43g00827586

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



    Illustration 44g00827587

  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" ".

Operational Check

  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. Reconnect the grounded battery cable to the battery.

  1. 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.

  1. 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.

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