Procedure to Rework 13.6 m (44.62 ft) Mast Encoder on Certain MD6250 Rotary Drills {1408} Caterpillar

Rotary Drill

MD6250 (S/N: DN71-102,105-106,108-108,110-112,117-119; DN8102-102)

Introduction

This special instruction provides the information to rework the mast encoder on certain machines listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Show/hide table

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Show/hide table

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

Show/hide table

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

Show/hide table

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

Show/hide table

Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Show/hide table

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

Show/hide table

Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Show/hide table

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

Show/hide table

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Rework Procedure

Structures Rework ( 578-0957 Mounting Bracket Gp)

Required Part

Rework procedure

Show/hide table

Illustration 1	g06422115
Before rework

1. To rework the crown, follow the set of instruction:

   • Remove and discard cab side sheave and retain hoist cable.

   • Remove and retain crown harness, depth encoder, and beacons.

   • Remove and retain crown chain link.

   • Cut cab side sheave bracket.

   Note: Repair and repaint the surface.

   Show/hide table

   Illustration 2	g06426483

   Show/hide table

   Illustration 3	g06426541
   Detail view of A (D1) 171.3 mm (6.74 inch) (D2) 104.8 mm (4.13 inch) (D3) 742.5 mm (29.23 inch) (D4) 700.5 mm (27.58 inch) (D5) 544 mm (21.4 inch) (D6) 447.5 mm (17.62 inch) (D7) 392.2 mm (15.44 inch) (D8) 332.2 mm (13.08 inch)

2. Drill four holes of diameter 18 mm (0.7 inch) on the plate as shown in Illustration 3 and Illustration 2.

Show/hide table

Illustration 4	g06426618
(1) 578-5758 Shim (2) 118-5805 Special Race Bearing (3) 487-5859 Position Sensor Gp (4) 240-6577 Threaded Rod (5) 487-5860 Position Sensor (6) 469-2140 Spacer (7) 578-0959 Sheave

Note: Apply Blue Loctite on both sides of threaded rod (4) (Loctite 242) and hand tighten threaded rod (4) and position sensor (5).

Note: If completed 578-0957 Mounting Bracket Gp is not received, perform procedure to assemble 578-0957 Mounting Bracket Gp.

Note: The retaining ring should be towards the sheave shoulder.

Note: To press the bearing onto the sheave shaft only apply force to the internal ring of the bearing. Continue to press until the bearing contacts the sheave shoulder

1. Install sheave (7) with bearing (2), shim packs (1), position sensor (3), threaded rod (4)( 40 ± 1.5 mm (1.6 ± 0.06 inch)), position sensor (5), and spacer (6) to 578-0957 Mounting Bracket Gp.

   Connect the hoist cable.

   Reference: Testing and Adjusting, M0074458, "Mast - Test and Adjust - Hoist Pulldown Auto Tension"

Illustration 5	g06422127
After rework

Rework Instruction for 578-2449 Automatic Lubrication Lines Gp

Location of Rework

Illustration 6	g06420209

Required Parts

Rework Procedure

Show/hide table

Illustration 7	g06418605
View of 561-7999 Automatic Lubrication Lines Gp (A) 533-6084 Hose As

1. Remove and discard hose assembly (A) from the eighth injector of automatic lubrication lines group.
   Show/hide table

   Illustration 8	g06418642
   View of 561-7999 Automatic Lubrication Lines Gp (1) 578-1843 Hose As

2. Install hose assembly (1) to eighth injector of automatic lubrication lines group.
   Show/hide table

   Illustration 9	g06419401
   (2) 004-6683 Fitting (3) 468-3120 Injector As (4) 3J-5390 Plug (5) 148-8320 Connector As (6) 148-8351 Elbow As (7) 420-0939 Spacer

3. Install injector assembly (3) to 269-5352 Lubrication Distribution Valve Gp using fitting (2).

4. Install plug (4), connector assembly (5), elbow adapter (6), and spacer (7) on injector assembly (3). Refer to Illustration 9.
   Show/hide table

   Illustration 10	g06419408
   (3) 468-3120 Injector As (8) 578-1841 Hose As

5. Install one end of hose assembly (8) to injector (3).
   Show/hide table

   Illustration 11	g06419418
   (B) 276-2970 Hose (8) 578-1841 Hose As (9) 5P-9299 Clip (10) 8T-4136 Bolt (11) 8T-4121 Hard Washer (12) 344-5675 Nut

6. Secure hose assembly (8) with hose assembly (B) using two clips (9), bolt (10), two washers (11), and nut (12).
   Show/hide table

   Illustration 12	g06419447
   (9) 5P-9299 Clip (11) 8T-4121 Hard Washer (13) 144-8344 Spacer (14) 8T-4182 Bolt

7. Secure 578-1841 Hose As using clip (9), washer (11), spacer (13), and bolt (14) in two locations.
   Show/hide table

   Illustration 13	g06419495
   (9) 5P-9299 Clip (15) 2R-1939 Clip

8. Secure 578-1841 Hose As using clip (9) and clip (15).
   Show/hide table

   Illustration 14	g06419531
   (D1) 630 mm (24.8 inch) (D2) 481 mm (18.9 inch) (W1) 2 x 6 mm (0.2 inch) all-around fillet weld (16) 8Y-3795 Boss

9. Weld two bosses (16) on the 507-5688 Tube as per dimension shown in Illustration 14.
   Show/hide table

   Illustration 15	g06419580
   (1) 578-1843 Hose As (8) 578-1841 Hose As (9) 5P-9299 Clip (11) 8T-4121 Hard Washer (16) 8Y-3795 Boss (17) 8t-4195 Bolt

10. Secure hose (8) using three clips (9), two washers (11), and two bolts (17) to boss (16).

11. Route hose (1) to the top of machine as shown in Illustration 15.
    Show/hide table

    Illustration 16	g06419666
    (8) 578-1841 Hose As (11) 8T-4121 Hard Washer (17) 205-7299 Clip (18) 8T-4137 Bolt

12. Secure hose (8) with two clips (17), two hard washers (18), and two bolts (18) in two locations.
    Show/hide table

    Illustration 17	g06419839
    (1) 578-1843 Hose As (8) 578-1841 Hose As (15) 2R-1939 Clip

    Show/hide table

    Illustration 18	g06419852
    (1) 578-1843 Hose As (8) 578-1841 Hose As (15) 2R-1939 Clip

    Show/hide table

    Illustration 19	g06427117
    (1) 578-1843 Hose As (8) 578-1841 Hose As (15) 2R-1939 Clip

13. Remove the existing 9M-4995 Clip, and secure hose (1) with hose (8) using seven clips (15) in three locations as shown in Illustration 17.
    Show/hide table

    Illustration 20	g06419885
    (1) 578-1843 Hose As (8) 578-1841 Hose As (15) 2R-1939 Clip (19) 204-2281 Cable Strap

14. Secure hose (1) with hose (8) using clip (15) and cable strap (19).
    Show/hide table

    Illustration 21	g06419903
    Top of mast (16) 8Y-3795 Boss (D3) 463 mm (18.2 inch) (D4) 22.5 mm (0.88 inch) (D5) 395 mm (15.5 inch) (D6) 357 mm (14.1 inch) (W2) 2 x 6 mm (0.2 inch) all-around fillet weld

15. Weld two bosses (16) as per the dimensions on plate shown in Illustration 21.
    Show/hide table

    Illustration 22	g06419956
    (1) 578-1843 Hose As (5) 148-8320 Connector As (8) 578-1841 Hose As (9) 5P-9299 Clip (10) 8T-4136 Bolt (11) 8T-4121 Hard Washer (15) 2R-1939 Clip

    Note: The bearing cavities must be manually filled with grease and the newly installed grease line must be purged prior to connecting to the sheave assembly. Use 6H-9049 Fitting to fill grease manually.

16. Install hose assembly (1) and hose (8) to bracket assembly using two adapters (5).

17. Secure hose assembly (1) with hose (8) using clip (15). Refer to Illustration 22.

18. Secure hose assembly (1) to welded boss (16) using clip (9), bolt (10), and washer (11). Refer to Illustration 22.

    Secure hose assembly (8) to welded boss (16) using clip (9), bolt (10), and washer (11). Refer to Illustration 22.

Rework Procedure for 578-5217 MAST WIRING GP

Location of Rework

Illustration 23	g06422343

Show/hide table

Illustration 24	g06420250
(1) 578-5211 Box Harness As (2) 7K-1181 Cable Strap

1. Install box harness (1) to 507-9074 Enclosure Ar.

2. Secure harness (1) with 574-9663 Box Harness As using five cable straps (2). Refer to Illustration 24.
   Show/hide table

   Illustration 25	g06420279
   (1) 578-5211 Box Harness As (2) 7K-1181 Cable Strap

   Show/hide table

   Illustration 26	g06420300
   Circuit Diagram

3. Connect the wires of harness (1) as:

   • Connect the M906-ED9-BU(Blue)wire to PIN43 of EL-C175.

   • Connect the M908-ED10-YL(Yellow)wire to PIN49 of EL-C175.

   • Connect the M909-ED11-GN(Green)wire to PIN50 of EL-C175.

   • Connect the N997-ED12-WH(White)wire to PIN41 of EL-C175.

   • Connect the N998-ED13-OR(Orange)wire to PIN42 of EL-C175.
   Show/hide table

   Illustration 27	g06420475
   (A) 155-2269 Connector Plug As (B) 3E-3364 Receptacle (1) 578-5211 Box Harness As (2) 7K-1181 Cable Strap

   Show/hide table

   Illustration 28	g06420750

4. Connect the wires of harness (1) as:

   • Remove J844-GY(Grey)wire from EL-C172 PIN 69.

   • Remove J843-BK(Black)wire EL-C172 PIN 56

   • Connect the J844-ED2-GY(Grey)wire to PIN 69 of EL-C172.

   • Connect the J843-ED5-BK(Black)wire to PIN56 of EL-C172.

   • Connect the T997-ED7-OR(Orange)wire to PIN11 of EL-C172.

   • Connect the T998-ED8-BR(Brown)wire to PIN21 of EL-C172.
   Show/hide table

   Illustration 29	g06420760
   (1) 578-5211 Box Harness As (2) 7K-1181 Cable Strap

   Show/hide table

   Illustration 30	g06420763

5. Connect the wires of harness (1) as:

   • Connect J844-ED3-GY(Grey)wire to EL-C2 PIN 100.

   • Connect J843-ED6-BK(Black)wire to EL-C2 PIN 101

   • Connect T997-ED7-OR(Orange)wire to EL-C2 PIN 110

   • Connect T998-ED8-BR(Brown)wire to EL-C2 PIN 111

   • Connect M906-ED9-BU(Blue)wire to EL-C2 PIN 104

   • Connect M908-ED10-YL(Yellow)wire to EL-C2 PIN 105

   • Connect M909-ED11-GN(Green)wire to EL-C2 PIN 106

   • Connect N997-ED12-WH(White)wire to EL-C2 PIN 112

   • Connect N998-ED13-OR(Orange)wire to EL-C2 PIN 113
   Show/hide table

   Illustration 31	g06420847
   (3) 578-5212 Valve Harness As (4) 7K-1181 Cable Strap

   Show/hide table

   Illustration 32	g06420860

6. Install one end of harness (3) to 264-5732 Connector Plug As of 507-9074 Enclosure Ar.

   Connect the wires of harness (3) as:

   • Connect J884-VD1-GY(Grey)wire to V-C520 PIN100

   • Connect J843-VD2-BK(Black)wire to V-C520 PIN101

   • Connect T997-VD3-OR(Orange)wire to V-C520 PIN110

   • Connect T998-VD4-BR(Brown)wire to V-C520 PIN111

   • Connect M906-VD5-BU(Blue)wire to V-C520 PIN104

   • Connect MD908-VD6-YL(Yellow)wire to V-C520 PIN105

   • Connect M909-VD7-GN(Green)wire to V-C520 PIN106

   • Connect N997-VD8-WH(White)wire to V-C520 PIN112

   • Connect N998-VD9-OR(Orange)wire to V-C520 PIN113
   Show/hide table

   Illustration 33	g06420887
   (3) 578-5212 Valve Harness As (2) 7K-1181 Cable Strap (C) 549-7674 Valve Harness As

7. Secure harness (3) with valve harness (C) using 17 cable straps (4).
   Show/hide table

   Illustration 34	g06420902
   (3) 578-5212 Valve Harness As (2) 7K-1181 Cable Strap

   Show/hide table

   Illustration 35	g06420910

8. Connect another end of harness (3) to 224-2734 Connector Receptacle As.

   Connect the wires of harness (3) as:

   • Connect J884-VD1-GY(Grey)wire to V-C16 PIN 48

   • Connect J843-VD2-BK(Black)wire to V-C16 PIN 49

   • Connect T997-VD3-OR(Orange)wire to V-C16 PIN 50

   • Connect T998-VD4-BR(Brown)wire to V-C16 PIN 51

   • Connect M906-VD5-BU(Blue)wire to V-C16 PIN 58

   • Connect M908-VD6-YL(Yellow)wire to V-C16 PIN 59

   • Connect M909-VD7-GN(Green)wire to V-C16 PIN 60

   • Connect M906-VD5-BU(Blue)wire to V-C16 PIN 61

   • Connect N998-VD9-OR(Orange)wire to V-C16 PIN 62
   Show/hide table

   Illustration 36	g06421382
   (2) 7K-1181 Cable Strap (4) 578-5213 Wiring Harness (E) 574-9669 Wiring Harness

   Show/hide table

   Illustration 37	g06421385

9. Install one end of harness (4) to 160-7689 Connector Plug As.

   Connect the wires of harness (4) as:

   • Connect J844-JD1-GY(Grey)wire to MJ-C6 PIN48

   • Connect J843-JD2-BK(Black)wire to MJ-C6 PIN49

   • Connect T997-JD3-OR(Orange)wire to MJ-C6 PIN50

   • Connect T998-JD4-BR(Brown)wire to MJ-C6 PIN51

   • Connect M906-JD5-BU(Blue)wire to MJ-C6 PIN58

   • Connect M908-JD6-YL(Yellow)wire to MJ-C6 PIN59

   • Connect M909-JD7-GN(Green)wire to MJ-C6 PIN60

   • Connect N997-JD8-WH(White)wire to MJ-C6 PIN61

   • Connect N998-JD9-OR(Orange)wire to MJ-C6 PIN62
   Show/hide table

   Illustration 38	g06421389
   (2) 7K-1181 Cable Strap (4) 578-5213 Wiring Harness (E) 574-9669 Wiring Harness

10. Secure harness (4) with mast flex harness (E) using six clips (2).
    Show/hide table

    Illustration 39	g06421394
    (2) 7K-1181 Cable Strap (4) 578-5213 Wiring Harness (E) 574-9669 Wiring Harness

11. Connect another end of harness (4) to 160-7689 Connector Plug As.

    Connect the wires of harness (4) as:

    • Connect J844-JD1-GY(Grey)wire to MJ-C2 PIN48

    • Connect J843-JD2-BK(Black)wire to MJ-C2 PIN49

    • Connect T997-JD3-OR(Orange)wire to MJ-C2 PIN50

    • Connect T998-JD4-BR(Brown)wire to MJ-C2 PIN51

    • Connect M906-JD5-BU(Blue)wire to MJ-C2 PIN58

    • Connect M908-JD6-YL(Yellow)wire to MJ-C2 PIN59

    • Connect M909-JD7-GN(Green)wire to MJ-C2 PIN60

    • Connect N997-JD8-WH(White)wire to MJ-C2 PIN61

    • Connect N998-JD9-OR(Orange)wire to MJ-C2 PIN62
    Show/hide table

    Illustration 40	g06421414
    (F) 574-9667 Wiring Harness (2) 7K-1181 Cable Strap (5) 578-5214 Sensor Harness As

    Show/hide table

    Illustration 41	g06421425

12. Install one end of harness (5) to 224-2734 Connector Receptacle As.

    Connect the wires of harness (5) as:

    • Connect J844-MD1-GY(Grey)wire to M-C413 PIN48

    • Connect J843-MD5-BK(Black)wire to M-C413 PIN49

    • Connect T997-MD9-OR(Orange)wire to M-C413 PIN50

    • Connect T998-MD10-BR(Brown)wire to M-C413 PIN51

    • Connect M906-MD11-BU(Blue)wire to M-C413 PIN58

    • Connect M908-MD12-YL(Yellow)wire to M-C413 PIN59

    • Connect M909-MD13-GN(Green)wire to M-C413 PIN60

    • Connect N997-MD14-WH(White)wire to M-C413 PIN61

    • Connect N998-MD15-OR(Orange)wire to M-C413 PIN62
    Show/hide table

    Illustration 42	g06421460
    (F) 574-9667 Wiring Harness (2) 7K-1181 Cable Strap (5) 578-5214 Sensor Harness As

13. Secure harness (5) with wiring harness (F) using 25 clips, as shown in Illustration 42.
    Show/hide table

    Illustration 43	g06421483
    (D1) 40 mm (1.5 inch) (D2) 1760 mm (69.3 inch) (H) MB-C2 connector (2) 7K-1181 Cable Strap (5) 578-5214 Sensor Harness As (6) 578-5216 Cable As

    Note: Dimension (D2) should be measured from mast base plate to bottom proxy switch mounting boss.

    Show/hide table

    Illustration 44	g06421512
    Detail view of G (W1) 2 x 6 mm (0.2 inch) all-around fillet weld (7) 9R-3761 Boss (8) 578-4259 Plate (9) 8T-4121 Hard Washer (10) 8T-4136 Bolt (11) 521-1761 Position Sensor Gp (12) 242-7386 Washer (13) 8T-0289 Bolt (14) 3T-0851 Locknut

    Show/hide table

    Illustration 45	g06427631
    Section J-J (D3) 378.7 mm (14.91 inch) (D4) 453.7 mm (17.86 inch) (D5) 2 x 65.9 mm (2.6 inch)

14. Connect harness (5) to MB-C2 connector.

    Secure MB-C2 harness connector (H) with harness (5) using clip as shown in Illustration 43.

15. Connect one end of cable assembly (6) to MB-C2 connector (H). Refer to Illustration 43.

16. Weld two bosses (7) to 526-2215 Tube as per the dimensions shown in Illustration 43, Illustration 45, and Illustration 44.

    Install plate (8) to boss (7) with four washers (12), two bolts (13), and two nuts (14), as shown in Illustration 44.

17. Install position sensor (11) to plate (8) using two washers (9) and two bolts (10) as shown in Illustration 44.

18. Connect another end of cable assembly (6) to position sensor (11). Refer to Illustration 44.
    Show/hide table

    Illustration 46	g06421532
    (F) 574-9667 Wiring Harness (2) 7K-1181 Cable Strap (5) 578-5214 Sensor Harness As

    Show/hide table

    Illustration 47	g06421553
    (F) 574-9667 Wiring Harness (2) 7K-1181 Cable Strap (5) 578-5214 Sensor Harness As

19. Secure and route harness (5) with harness (5) using 44 clips towards the crown.
    Show/hide table

    Illustration 48	g06427647
    (K) connector (MB-C1 mate with MT-C1) (2) 7K-1181 Cable Strap (5) 578-5214 Sensor Harness As (15) 578-5215 Sensor Harness As

20. Connect harness (5) to MB-C1 and mate with MT-C1.

    Secure connector (K) (MB-C1 mate with MT-C1) with 574-9667 Wiring Harness using clip (2).

    Show/hide table

    Illustration 49	g06427654
    (2) 7K-1181 Cable Strap (5) 578-5214 Sensor Harness As

21. Secure harness (5) with 574-9667 Wiring Harness using 15 clips and route hose assembly as shown in Illustration 49.
    Show/hide table

    Illustration 50	g06427667
    (W2) 2 x 6 mm (0.2 inch) all-around fillet weld (D6) 175 mm (6.9 inch) (D7) 285 mm (11.2 inch) (D8) 7153 mm (281.6 inch) (D9) 120 mm (4.7 inch) (D10) 40 mm (1.6 inch) (5) 578-5214 Sensor Harness As (6) 578-5216 Cable As (9) 8T-4121 Hard Washer (10) 8T-4136 Bolt (11) 521-1761 Position Sensor Gp (12) 242-7386 Washer (13) 8T-0289 Bolt (14) 3T-0851 Locknut (16) 7T-1099 Link (17) 9R-3761 Boss (18) 578-4259 Plate

    Note: Dimension (D8) should be measured from mast base plate to bottom proxy switch mounting boss.

    Show/hide table

    Illustration 51	g06427683
    Section L-L (D11) 493.5 mm (19.43 inch) (D12) 568.5 mm (22.38 inch) (D13) 2 x 65.9 mm (2.6 inch)

22. Secure harness (5) with 574-9667 Wiring Harness using weld link (16).

    Connect harness (5) to MB-C3 connector.

    Connect one end of cable assembly (6) to MB-C3 connector.

23. Secure cable (6) with MB-C3 connector using weld link (16) as shown in Illustration 50.

24. Weld two bosses (17) as per the dimensions shown in Illustration 50 and Illustration 51.

    Install plate (18) to boss (17) using four washers (12), two bolts (13), and two nuts (14). Refer to Illustration 50.

25. Install position sensor (11) to plate (18) using two washers (9) and two bolts (10). Refer to Illustration 50.

    Connect another end of cable assembly (6) to position sensor (11). Refer to Illustration 50.

    Show/hide table

    Illustration 52	g06427692
    (M) 580-1188 Wiring Harness (2) 7K-1181 Cable Strap (15) 578-5215 Sensor Harness As

26. Secure and route harness (15) with mast harness (M) with 16 clips (2).
    Show/hide table

    Illustration 53	g06427697
    (D14) 65 mm (2.6 inch) (D15) 240 mm (9.5 inch) (D16) 230 mm (9.1 inch) (D17) 230 mm (9.1 inch) (M) 580-1188 Wiring Harness (2) 7K-1181 Cable Strap (15) 578-5215 Sensor Harness As (16) 7T-1099 Link

27. Secure harness (15) with harness (M) using six cable straps (2) and six links (16).
    Show/hide table

    Illustration 54	g06427753
    (W3) 2 x 6 mm (0.2 inch) all - around fillet weld (D18) 80 mm (3.2 inch) (D19) 180 mm (7.1 inch) (D20) 180 mm (7.1 inch) (D21) 238 mm (9.4 inch) (D22) 13441 mm (529.2 inch) (D23) 115 mm (4.5 inch) (D24) 40 mm (1.6 inch) (M) 580-1188 Wiring Harness (2) 7K-1181 Cable Strap (6) 578-5216 Cable As (9) 8T-4121 Hard Washer (10) 8T-4136 Bolt (11) 521-1761 Position Sensor Gp (15) 578-5215 Sensor Harness As (16) 7T-1099 Link (17) 9R-3761 Boss (18) 578-4259 Plate

    Note: Dimension (D22) should be measured from mast base plate to bottom proxy switch mounting boss.

    Show/hide table

    Illustration 55	g06427864
    Section of N-N (D25) 730.6 mm (28.76 inch) (D26) 805.6 mm (31.72 inch) (D27) 2 x 65.9 mm (2.60 inch)

28. Secure harness (15) with 580-1188 Wiring Harness using seven cable straps (2) and seven welded links (16) as shown in Illustration 54.

29. Connect harness (15) to MB-C3 connector.

    Connect one end of the cable assembly (6) to MB-C3 connector as shown in Illustration 54.

30. Weld two bosses (17) as per the dimension shown in Illustration 54 and Illustration 55.

    Install plate (18) to boss (17) using four washers (12), two bolts (13), and two nuts (14). Refer to Illustration 54.

31. Install position sensor (11) to plate (18) using two washers (9) and two bolts (10). Refer to Illustration 54.

    Connect another end of cable assembly (6) to position sensor (11). Refer to Illustration 54.

    Show/hide table

    Illustration 56	g06427911
    (M) 580-1188 Wiring Harness (2) 7K-1181 Cable Strap (15) 578-5215 Sensor Harness As

32. Secure and route harness (15) with harness (M) using 12 cable straps (2).
    Show/hide table

    Illustration 57	g06427936
    (M) 580-1188 Wiring Harness (2) 7K-1181 Cable Strap (15) 578-5215 Sensor Harness As (19) 200-6345 Mounting Saddle

33. Secure and route harness (15) with harness (M) using eight clips (2) and two mounting swivels (19) towards the crown. Refer to Illustration 57.

34. Connect harness (15) to 578-0957 Mounting Bracket Gp. Refer to Illustration 57.
    Show/hide table

    Illustration 58	g06427947
    Installation of target plate (W4) 2 x 6 mm (0.2 inch) all-around fillet weld (D28) 141 mm (5.5 inch) (D29) 100 mm (3.9 inch) (D30) 25 mm (1.0 inch) (17) 9R-3761 Boss

35. Weld two bosses (17) as per the dimensions shown in Illustration 58.
    Show/hide table

    Illustration 59	g06427959
    (9) 8T-4121 Hard Washer (10) 8T-4136 Bolt (20) 578-4292 Plate

36. Install plate (20) to welded boss with two washers (9) and two bolts (10).
    Show/hide table

    Illustration 60	g06422071
    (P) 566-5662 Position Sensor Gp (R) 524-5322 Cable As

37. Remove and discard position sensor (P) and cable assembly (R).

New Encoder Calibration and Troubleshooting

Depth Measurement

The normal process for depth processing is as follows:

1. At key-ON we read from memory the last known head position to use as the start point.

2. The rotary encoder reads the position of one top cable sheave and calculates the motion of the rotary head.

3. After the rotary head passes each proximity switch the position is adjusted to be more accurate.

4. At key-OFF the position will be saved into memory.

The proximity switches are placed before the head reaches important locations:

• Pipe in the hole for two pipe masts (optional switch).

• Head clear of carousel and pipe in the hole for one pipe masts.

• Head near deck wrench.

Diagnostics

The sheave encoder has diagnostics for open and short to ground diagnostics. If there is a failure, all interlocks that use head position are activated and they will need to be manually overridden.

• If a failure is detected with duty cycle (raw input from sensor), head above carousel, head cleared to positioner and pipe not in hole interlocks will be activated. The operator will need to override these to perform related operations.

• If a failure is detected with all the proximity switches (that are part of the depth system based on machine configuration), head above carousel, head cleared to positioner and pipe not in hole interlocks will be activated. The operator will need to override these to perform related operations.

• If a failure is detected with one (any) proximity switch (that is part of the depth system based on machine configuration), automatic pipe handling will not work.

The proximity switches have short to ground diagnostics to avoid improper position corrections.

Component Detail

The sheave sensor uses hall effect technology that senses a magnet that is attached to the sheave.

The proximity switches are typical proximity switches that are mounted on the mast and will read the target mounted on the rotary head guides.

1^st Time Calibration

To calibrate the head position the rotary head needs to be moved up or down past one of the proximity switches. Once the proximity switch is flagged the calibration is complete. There is no longer a need to calibrate through the operator display. Those buttons may be present in current software but will be removed shortly. You may have an event stating that top of mast calibration is required, this will be removed from software as well in a future release.

Verify ET settings

• It is important to verify mast length and pipe length settings in ET are correct for the machine’s configuration. These are critical for the new software.

Depth System Configuration MD6250

• 13.6 m (44.62 ft) mast and 6096 mm (240.0 inch) pipe.

New Encoder Calibration 13.6 m (44.62 ft) Mast with 6.1 m (20 ft) Pipe

1. Install CAT Electronic Technitian 2019A provided directly from the Drill product group.
   Show/hide table

   Illustration 61	g06425807

   Show/hide table

   Illustration 62	g06425822

2. Connect to ET and go to configuration page.

   • Connect via common adapter.

   • Go to configuration page in ET.
   Show/hide table

   Illustration 63	g06425859

3. Mast Configuration

   • Set mast length to 13.6 m (44.6 ft).

Electrical Troubleshooting

Illustration 64	g06420279

• Connect the M906-ED9-BU(Blue)wire to PIN43 of EL-C175 - signal from proximity switch, should read 5V when target not detected and 1.3V when target is detected.

• Connect the M908-ED10-YL(Yellow)wire to PIN49 of EL-C175 - signal from proximity switch, should read 5V when target not detected and 1.3V when target is detected.

• Connect the M909-ED11-GN(Green)wire to PIN50 of EL-C175 - signal from proximity switch, should read 5V when target not detected and 1.3V when target is detected.

• Connect the N997-ED12-WH(White)wire to PIN41 of EL-C175 Pin 3 on Encoder Sig 1 (This should see 5 to 95% duty Cycle when head is moving) against the ground).

• Connect the N998-ED13-OR(Orange)wire to PIN42 of EL-C175 Pin 4 on Encoder Sig 2(This should see 5 to 95% duty Cycle when head is moving) against the ground).

Note: Mast that are 11.2m with 35ft carousel should use only M906 and M908.

Illustration 65	g06420475

• Remove J844-GY(Grey)wire from EL-C172 PIN 69.

• Remove J843-BK(Black)wire EL-C172 PIN 56

• Connect the J844-ED2-GY(Grey)wire to PIN 69 of EL-C172.

• Connect the J843-ED5-BK(Black)wire to PIN56 of EL-C172.

• Connect the T997-ED7-OR(Orange)wire to PIN11 of EL-C172 - Pin 1 on Encoder vs (needs to read 5V).

• Connect the T998-ED8-BR(Brown)wire to PIN21 of EL-C172 - Pin 2 on Encoder ground.