NEHS0730-03 Tool Operating Manual 168-7720 Ultrasonic Wear IndicatorIII Group

NEHS0730-03 11 September 2013
Tool Operating Manual

i04778305
168-7720 Ultrasonic Wear Indicator III Group

SMCS Code: 0374; 0599; 0729; 0787
Caterpillar Products All
Table of Contents
Introduction ...........................................................2 Literature Information .............................................2 Safety Section....................................................2 General Information Section ................................3 Operation Section...............................................3 Maintenance Section ..........................................3 Service Parts Section..........................................3 Safety Icon Nomenclature ...................................3 Personal Protection/Important Information....................................................3 Prohibited Action .............................................3 Hazard Avoidance...........................................3 General Information ...............................................3 Introduction ........................................................3 Additional Contact Information .............................4 Other Uses for The Indicator III ............................4 Benefits Ultrasonic Wear Indicator III....................4 Features of the Indicator III...............................4 General Measurement Benefits............................4 Undercarriage Measurement Benefits ..................5 168-7720Ultrasonic Wear Indicator III Group..................................................................5 Storage Of Conventional Tools ............................5 Optional Items ....................................................6 168-7720Ultrasonic Wear Indicator III Group Specifications . . . . . . . . . . . . . . . . . . . . . . . . .6 168-7722Ultrasonic Probe Specifications ...................................................7 156-1077Power Inverter Specifications ...................................................7 Connections to the 168-7721Indicator III.............8 168-7721Indicator III Description.......................................................8 Abbreviations and Descriptions Used on Front Panel and Key Pad ...............................8
Charging the Internal NiCad (rechargeable) Batteries ........................................................10 Procedure.....................................................10 Replacing The Internal Rechargeable Batteries ..................................................... 11 Connecting To DC power...................................12 Care and Cleaning Of 168-7721Indicator III...................................................................13 Remove the 9U-7981Couplant Residue ............13 Cleaning the Case and Front Panel Key Pad ............................................................13 Care of Connectors .......................................13 Operating Instructions for 168-7721Indicator III ......................................................................13 Turn the Indicator III ON ....................................13 Calibrating the Indicator III Probe .......................14 Undercarriage Measurement Procedure .............15 Clearing The Memory........................................15 Using LOC(ation) Mode of Operation..................16 List of Undercarriage Storage LOC(ation) Displays......................................................16 Entering Information into the Indicator III.............17 Changing Displays with Words ..........................18 Measuring Track Sag ........................................18 Taking Ultrasonic Measurements .......................18 Saving Measured Values in Memory...................19 Tool Displays....................................................19 Measurement Operating Tips.............................19 Undercarriage Measurement Techniques...............20 Track Links ......................................................20 Track Shoes.....................................................20 Track Bushing ..................................................20 Idler.................................................................21 Carrier Roller....................................................21 Three Piece Rims..........................................21 Track Roller......................................................22 Competitive Parts .............................................22 Measuring the Thickness of Parts Other than Undercarriage.................................................22 Transferring the Memory Values To or From a Computer ..........................................................22 Settings Menu .....................................................24 Resolution........................................................27 Turnoff.............................................................27 Velocity............................................................27 Serial...............................................................27 Beeper ............................................................27 Language ........................................................27
Distance ..........................................................27 Date ................................................................27 Ultrasonic Velocity Adjustment ..............................27 Checking the Ultrasonic Velocity ........................28 Changing the Ultrasonic Velocity........................28 Battery Level Monitor ........................................29 Low Battery Indication.......................................29 Return to Last Menu Screen ..............................29 Factory Reset...................................................29 Viewing the Software Version Screen .................29 Checking the Operation of the Indicator III...................................................................30 Alternate Method...........................................30 Adjusting the Display Contrast ...........................30 Adjusting the Gain ............................................30 Troubleshooting ...................................................31 Undercarriage Measurement Display Map..............31 Location Display Map ...........................................33 9U-7981Couplant Material Safety Data Sheet ................................................................36 Service ...............................................................37
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING, or CAUTION. The Safety Alert WARNING label is shown below. A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures. The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Introduction
Important Safety Information
Illustration 1
g02139237
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication. Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Think Safety
European Union Compliant, CE Marked 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 to perform these functions properly. Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety Section
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
Prohibited Action No smoking
General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources. Hazard Avoidance Crushing hazard (foot)
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator. Photographs and illustrations guide the operator through correct procedures for using the tool group.
Crushing hazard (hand)
Pinch point
Fire hazard Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Electrical Shock - Hazard
Maintenance Section
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal Fire hazard
Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.
General Information
Introduction
Safety Icon Nomenclature

Personal Protection/Important Information
Illustration 3
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168-7721 Ultrasonic Wear Indicator III
The 168-7720 Ultrasonic Wear Indicator III Group provides a new, fast, and accurate method of measuring track-type machine undercarriage wear. By placing a probe on the part to be measured, the Ultrasonic Wear Indicator III will show the part thickness on the two-line alpha numeric display. The indicator also guides the operator by indicating the undercarriage components to be measured. The thickness values can be stored in internal memory for recall later. This stored information may be transferred to a computer for printing.
Illustration 2
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Personal Protection/Important Information
The Custom Track Service (CTS) personal computer program is available and when used with the Ultrasonic Wear Indicator III, will provide undercarriage wear reports directly from the stored measurements. This new CTS tool provides a professional alternative for the mechanical CTS tool kit. The Ultrasonic Wear Indicator III measures the part thickness by sensing high frequency sound waves through the material to be measured. When the sound reaches the opposite side of the part, sound is reflected back and received by the probe. The time required for the sound to travel through the part and be received determines the thickness of the part. The microprocessor in the Indicator III converts the time into a thickness value and displays value. When taking measurements. The 9U-7891 Couplant must be applied to the sensing end of the probe before measuring. This allows the sound to be transferred into the part being measured. For convenience, the couplant container attaches to the side of the Indicator III.
Features of the Indicator III New design uses state-of-the-art surface mount electronics for high reliability. For battery access - loosen the two battery cover screws on the back of the Indicator III. Backlit Liquid Crystal Display can be turned ON or OFF. Power Level Monitor shows estimated battery power remaining in percent. Mono earphone connector accepts earphone to hear beeper when working in a noisy environment. Built-in multiple language capability with English, Portuguese, French, Spanish, and German languages. Program modules no longer needed to switch languages. 168-7720 Ultrasonic Wear Indicator III Group includes an updated probe with a longer, more durable cable.
Additional Contact Information

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at: USA 1-800-542-8665, Option 1 International 1-309-578-7372
Used with Custom Track Service (CTS) inspections, which can be downloaded directly to a computer for viewing or printing. Uses five Alkaline or NiCad AA batteries (no battery pack). Automatically recalls and shows last machine or location display screen used when turned ON. When transferring machine data from a PC to the Indicator III, the user can select where the data will be stored.
Other Uses for The Indicator III

Quick and accurate, nondestructive thickness measuring of track beds, truck bed liners, bulldozer blades, bucket base edges, bucket cutting edges, scraper bowls, and even materials like aluminum, plastic, copper, and glass.
General Measurement Benefits

Higher accuracy measurements. Digital display of thickness is accurate to 0.10 mm (0.004 inch) for low-resolution mode, and 0.01 mm (0.0004 inch) for high-resolution mode. Time savings in measuring undercarriage due to reduced cleaning and measurement storage. Easy to use. Thickness reading will always appear on the display when the probe is used, regardless of mode of operation. Calibrated for undercarriage steel, but velocity can be adjusted to measure other materials such as aluminum, plastic, and glass. Reads thickness of parts where opposite side is not accessible, such as a bulldozer blade, bucket base ledge, or scraper bowl thickness. No writing. Stores readings in memory, then transfers to a computer for printing.
Benefits Ultrasonic Wear Indicator III

For many years, CTS inspectors have used the mechanical CTS kit to measure undercarriage wear. While this method worked, the new Ultrasonic Wear Indicator III has many benefits over the previous measurement method. These features and benefits are listed below.
Undercarriage Measurement Benefits

Less time cleaning parts. Only a small surface on the wear area must be cleaned. On bushings, the back side, between the bushing and shoe, does not require cleaning. Measures track idler center flange thickness. Eliminates errors caused by dirt packed around parts. Accurately measures bushing wear after turning. Stores information from 64 machines. All CTS inspectors measure with the same accuracy because the CTS computer program directly calculates percent wear and projected life. Prompts CTS inspector on next reading location.
(Table 1, contd) (7) Paper Towels (16 sheets from 9U-6000 Paper Towel Case) 168-7720 Group Label (located in lid of carrying case) Four 1-9/16 inch protective caps for RS232 connector Ultrasonic Wear Indicator III Group Tool Operating Manual
NEHS2835 NEHS0730
Storage Of Conventional Tools
168-7720Ultrasonic Wear Indicator III Group
Illustration 5
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Storage For Conventional CTS Tools In 6V-7145 Carrying Case Refer To Table 2 For Item Identification Table 2 Storage Locations Item (1)
Illustration 4 g02901717
Part No. PEKP9400 5P-3277 8H-8580 5P-8616 5P-8617 6V-9410 5P-3920
Description Custom Track Service Handbook: Fits under Indicator III Tape Measure: 3 m (9.8 ft) for pitch, sag, and sprocket measurement Scraper: For cleaning undercarriage components Sprocket Gauge: For D4, D5, and D6 Track-Type Tractors Sprocket Gauge: For D7, D8, and D9 Track-Type Tractors Depth Gauge: For measuring idlers Steel Rule: 300 mm (11.8 inch), store on top of 9U-6000 Paper Towels
168-7721 Ultrasonic Wear Indicator III Refer To Table 1 for Item Identification
(2) (3)
Table 1 168-7721 Ultrasonic Wear Indicator III Item (1) (2) (3) (4) (5) (6) Part No. 168-7721 168-7722 9U-7981 6V-7145 4C-4772 4C-3024 Description Ultrasonic Wear Indicator III (Calibration Certificate not shown) Ultrasonic Probe (Declaration of Conformity not shown) Couplant Carrying Case Foam Insert Battery Charger (110/220 VAC, 50/60 Hz) (5) (6) (4)
(continued)
Conventional CTS tools can be stored with the 168-7720 Ultrasonic Wear Indicator III Group. Because some undercarriage components cannot be measured with the 168-7721 Ultrasonic Wear Indicator III, provisions have been made for storing the required conventional CTS tools in the carrying case. These tools are not provided with the group, but may be ordered separately.
Note: The part numbers for other conventional undercarriage tools can be found in the CTS Handbook.
(Table 3, contd) Additional Service Replacement Part (not shown) Couplant Holder: The service replacement for the holder that stores the 9U-7981 Couplant container.
Optional Items
4C-5490
Note: Five batteries are required to power the 168-7721 Ultrasonic Wear Indicator III. NOTICE DO NOT attempt to recharge alkaline batteries using the 4C-3024 Battery Charger. Attempting to charge an alkaline battery can result in damage to the 168-7721 Ultrasonic Wear Indicator III. Place a piece of tape over the charge connector, to prevent charging, when using alkaline batteries.
Optional Items For 168-7721 Ultrasonic Wear Indicator III Table 3 Optional Items Item (1) Part No. 4C-5488 Description Cable Assembly RS232 (PC AT Version): For connecting the 168-7721 to an IBM AT, or compatible, personal computer. Has 9-pin, type D connector (DB9F). Cable Assembly RS232 (PC XT Version): For connecting the 168-7721 to an IBM XT, or compatible, personal computer. Has 25-pin, type D connector (DB25F). Cable Assembly RS232 (Modem Cable): For connecting the 168-7721 to a modem which transfers data over telephone lines to a personal computer. NiCad (Nickel Cadmium) Rechargeable Battery: (size AA) 1 per package. Alkaline Battery: Non-rechargeable battery (size AA) 96 per package. Power Inverter: For powering the 168-7721 from 12 VDC and includes battery cables and a cigarette lighter. Soft Protective Case: For protecting the 168-7721 during use. Custom Track Service (CTS) software program for transferring stored measurements from the 168-7721 to an IBM PC, or compatible, computer for storage or printing. Also required when a modem is used.
(2)
4C-5489
Illustration 7
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(3)
4C-5897
168-7721 Ultrasonic Wear Indicator III With 168-7722 Probe Installed in 9U-6175 Soft Protective Case
(4) (5) (6)
1U-7445 1U-9533 156-1077
168-7720Ultrasonic Wear Indicator III Group Specifications

Power Supplied By: ........ 5 NiCad (Nickel Cadmium), rechargeable batteries (size AA) or non-rechargeable 1U-9533 Alkaline Batteries. Note: The five AA batteries are accessed by removing the Indicator III back cover. See the Section Replacing The Internal Rechargeable Batteries for the procedure. NOTICE DO NOT attempt to recharge alkaline batteries using the 4C-3024 Battery Charger. Attempting to charge an alkaline battery can result in damage to the 168-7721 Ultrasonic Wear Indicator III. Place a piece of tape over the charge connector, to prevent charging, when using alkaline batteries.
(7) -
9U-6175 -
(continued)
Approximate Battery Life (with Indicator III backlight OFF and beeper ON) NiCad Rechargeable ....................................19 Hours Alkaline Non-rechargeable ...........................47 Hours Approximate Battery Life (with Indicator III backlight and beeper ON) NiCad Rechargeable ....................................14 Hours Alkaline Non-rechargeable ...........................34 Hours Indicator III shuts down .....................................5.12 V Power Line Operation: 4C-3024 Battery Charger .......110 VAC or 220 VAC, 50/60 Hz Measurement Range (Steel) .............. 1.27 to 254 mm (0.050 to 10.0 inch) Measuring Resolution: Low Resolution (default) ........... 0.1 mm (0.004 inch) High Resolution ....................0.01 mm (0.0004 inch) Measurement Accuracy: Low Resolution (default) ........... 0.1 mm (0.004 inch) High Resolution ....................0.076 mm (0.003 inch) Operating Temperature: ..........................18 to 60C (0.4 to 108.0F) Storage Temperature:
Weight: 168-7720 Group ....................................3 kg (6.6 lb) 168-7721 Indicator III ......................... 0.9 kg (2.0 lb) 168-7722 Probe ..........................0.113 kg (0.249 lb)
168-7722Ultrasonic Probe Specifications

Probe Type .................Dual Element 7.5 MHz special application Probe Size: Measuring Surface Diameter ............11 mm (0.4 inch) Length...............................................42 mm (1.7 inch) Diameter........................................... 19 mm (0.8 inch) Allowable Surface Temperature ............18 to 150C (0.4 to 270.0F) Cable Length .............................. 1524 mm (60.0 inch) Includes Certificate of Conformity
156-1077Power Inverter Specifications

Input Voltage Range ........................10.5 to 14.5 VDC Input Voltage Protection .... Automatically shuts down if voltage exceeds 15 VDC (the inverter will be damaged if connected to a 24 VDC battery) Low Battery Indicator ....Audible alarm sounds if input voltage drops to 10.6 VDC Output ........................................................... 115 VAC
Without Batteries Installed.......................40 to 60C (40.0 to 108.0F) With Alkaline Batteries Installed (less than 6 months) ....................................40 to 50C (40.0 to 90.0F) With NiCad Batteries Installed (less than 6 months) ....................................20 to 45C (4.00 to 81.0F) Memory Size: Flash Memory ........................................32,768 Bytes Random Access Memory (RAM) .............. 1024 Bytes Electrically Erasable Memory ................49,830 Bytes RS232 Specifications ............1200, 9600 (default), or 19,200 Baud rate LCD Backlit Display ..................2 Line x 16 Character External Dimensions: 6V-7145 Carrying Case ...........432 x 390 x 114 mm (17.0 x 15.4 x 4.5 inch) 168-7721 Indicator III .................190 x 168 x 40 mm (7.5 x 6.6 x 1.6 inch)
Operating Temperature Range:..............10 to 26.7C (50.0 to 48.06F) Over Temperature Protection: ..........When the power inverters internal heat sinks reach 65.5C (150 F), the inverter will automatically shut down. The inverter may be restarted by first disconnecting the inverter and allowing to cool for 15 minutes before reconnecting. No Load Current Draw ....................... Less than 0.2 A Output Receptacle ................................. Dual 3-prong Fuse ...........................................35 Amp (spade type) Weight ................................................. 1.6 kg (3.53 lb) Dimensions....................................155 x 127 x 58 mm (6.1 x 5.0 x 2.3 inch) Maximum Continuous power ............................300 W Surge Capability (Peak Power) ........................ 600 W Overload Protection ........ Inverter automatically shuts down if continuous power is greater than 300 W
Connections to the 168-7721Indicator III
(Table 4, contd) (6) Probe Connector Used to install the 168-7722 or 4C-5485 Ultrasonic Probe Earphone Connector (mono) Used to connect earphone to hear beepers sound in noisy environments. The beeper can only be heard when an earphone jack is installed in the earphone connector.
(7)
168-7721Indicator III Description
Illustration 8
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Connectors For 168-7721 Indicator III Refer to Table 4 for item identification. Table 4 Connectors For 168-7721 Indicator III Item (1) Part No. 9U-7981 Description Couplant Stored in pump-type dispenser. A small amount of couplant must be applied to the sensing end of the 168-7722 Ultrasonic Probe, before measuring, to couple ultrasonic sound into the material being measured. Holder Used to hold the 9U-7981 Couplant Dispenser Steel Calibration Disk The disk is used to check the accuracy of the wear indicator and recalibrate the wear indicator, if necessary. For additional information, refer to the Section Calibrating the Indicator III Probe in this manual. Connector (shown without 1 9/16 inch protective cap installed) Used to connect 4C-5488 Cable Assembly RS232 (PC AT) or 4C-5489 Cable Assembly RS232 (PC XT) or 4C-5897 Cable Assembly RS232 (Modem Cable) These cables can be used to transfer stored undercarriage data from the 168-7721 to a personal computer or printer. Refer to the Section Optional Items in this manual, for each cables-specific function and software program requirements. Charger Connector Used to connect the Battery Charger when recharging the rechargeable Batteries (NiCad). Also used to power the 168-7721 with the 4C-3024 Battery Charger. The plug of the 4C-3024 can be plugged into the 156-1077 Power Inverter to provide 12 VDC power for powering the indicator.
(2)
4C-5490
(3)
(4)
RS232
168-7721 Indicator III Front Panel And Key Pad
Abbreviations and Descriptions Used on Front Panel and Key Pad 1. MACH: Machine, referred to as MACH(ine) in this manual. 2. 6.3 mm (0.25 inch): Describes the metal calibration disk thickness measured in millimeters and inches during probe calibration (metal calibration disk is located on top panel). 3. RS232:
(5)
(continued)
Identifies connector located on top panel which provides the RS232 signal connection, for the optional cables, for transferring data to a personal computer. Refer to the Section Optional Items in this manual for each cables-specific function, software requirements, and use with the 168-7721 Indicator III. 4. CHARGE: Identifies the connector, located on top panel, for the 4C-3024 Battery Charger. 5. PROBE: Identifies the connector, located on the top panel, for the 168-7722 or 4C-5485 Ultrasonic Probe. 6. LOCATION & LOC: Location, referred to as LOC(ation) in this manual. Refers to undercarriage data locations. Description of Displays and Keys 7. MACH(ine) DISPLAY: Identifies the machine number (from 1 to 64) corresponding to the information on the display. When data is saved, data can be located later by going to this machine number. 8. LOCATION Display: Shows the undercarriage storage LOC(ation) display selected by the up or down arrow keys and shows the machine model when in the MACH(ine) mode of operation. The display, in Figure 9, is in the LOC(ation) mode. 9. MEASURED VALUE: Displays the thickness value being measured or the value of the last measurement taken. MM or IN will appear to the right of the value displayed, when measuring, to show that the probe is properly coupled to the material. 10.MEMORY VALUE: Displays the stored value for the location shown under MACH and LOCATION when in the LOC (ation) mode of operation. The machine serial (product identification) number is displayed here when in the MACH(ine) mode of operation. 11.SAVE/SET: This key will provide one of two functions: SAVE: Press to store the MEASURED VALUE in the MEMORY VALUE location. After the value is saved, the display will automatically advance to the next LOCATION. SET: Press and release the blue SHIFT key and then the SET key to enter the Setting Menu. Perform the same keystrokes to exit the Settings Menu.
12.MM/IN: Changes the display values from MM (millimeter) to IN (inch) and will work only when a value is on the display. Also used to show ultrasonic velocity. Refer to the Section Velocity in this manual. 13.PROBE CAL: Calibrates the ultrasonic probe so the Indicator III will read accurately. To use, apply couplant to the sensing end of the probe and press probe to the metal calibration disk on top of the Indicator III. If the MEASURED VALUE display is not 6.3 mm (0.25 inch) while in the Low Resolution mode, press PROBE CAL while holding the probe on the disk and display should read correctly. If the MEASURED VALUE display is not in the range of 6.25 to 6.32 mm (0.246 to 0.249 inch) while in the High Resolution mode, press PROBE CAL while holding the probe on the disk and display should read correctly. Refer to the Section Calibrating the Indicator III Probe and the Section Ultrasonic Velocity Adjustment in this manual. 14.ON/OFF: Turns Indicator III ON or OFF. Indicator III will automatically turn OFF after 5 minutes if not in use. This function can be disabled in the Settings Menu. Refer to the Section Settings Menu in this manual. 15.CLR/CLR MACH: This key will provide one of two functions: CLR will erase the character under the flashing cursor in the LOC(ation) mode). CLR MACH clears all MEMORY VALUE information from storage for the MACH(ine) number shown on the display or ALL 64 MACHINES. Note: Press and release the red SHIFT key and then CLR MACH key to enter the CLR MACH screen. The top line of the display will show CLR MACH and then the number of the machine to be cleared. Press the VALUE key to clear this machine. To clear all machines, first press the up or down arrow key to move the cursor to the bottom line of the display showing CLR ALL MACH. Press the VALUE key. 16.LOC/MACH: Changes from the MACH(ine) mode to the LOC (ation) mode of operation. In the MACH(ine) mode, the LOCATION display will show the letters MACH. Use the up or down arrow keys to move to any of the 64 machine storage locations.
In the LOC(ation) mode, the LOCATION display does not show the letters MACH, but instead describes the inspection information or undercarriage measurement location. Use the up or down arrow keys to move to any of the individual measurement locations for the MACH(ine) number shown in the upper left of the display. 17.LEFT ARROW, A or B: This key will provide one of two functions: In the LOC(ation) mode, the flashing cursor is moved one position to the left for each key press. When preceded by pressing either the red or blue SHIFT key, the corresponding colored character is entered on the display. 18.UP ARROW / BACKLIGHT: This key will provide one of two functions: UP ARROW: If LOCATION display reads MACH: Press the up arrow key to advance to the next MACH(ine) number. This is the MACH(ine) mode of operation. If LOCATION display does not read MACH, press the up arrow key to advance to the next measurement location. This is the LOC(ation) mode of operation. Hold the up arrow key to scroll in the MACH(ine) or LOC(ation) Display Mode. BACKLIGHT: Press and release the blue SHIFT key, then press this key to turn ON the display backlight. Perform the same keystrokes to turn the backlight OFF. Note: When Ultrasonic Wear Indicator III is in Manual Turn off mode (selectable in the settings menu): If backlight is ON, no key has been pressed, and probe not coupled for 5 minutes, then the backlight will turn OFF. The backlight will automatically turn ON when a key is pressed or probe is coupled. 19.DOWN ARROW: Use to move the display in the opposite direction as the up arrow. Note: Arrow keys will change display once every time pressed or may be held down to scroll (change) the display at a faster rate. 20.VALUE and RIGHT ARROW: VALUE: Used for manual entry of values when in the LOC(ation) mode. When pressed, a digit on the display will flash: Enter the desired characters. Press SAVE to leave the display as selected.
If a word appears for MEMORY VALUE: Press VALUE to select other words available. Press SAVE to leave the display as selected RIGHT ARROW: Used to move the flashing cursor to the right one character for each key press. Note: Pressing and holding this key will scroll the flashing cursor at a faster rate. 21.SHIFT (blue): Used to enter any blue character from the key pad. 22.SHIFT (red): Used to enter any red character from the key pad. Note: The SHIFT keys are to be pressed and released before pressing the desired character key. 23.Alphanumeric keys: These keys are used to enter directly, into the display, any information the user wishes to enter into storage when in the LOC(ation) mode.
Charging the Internal NiCad (rechargeable) Batteries
Illustration 10
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Rear View Of 4C-3024 Battery Charger
The 168-7720 Ultrasonic Wear Indicator III Group is supplied with a 4C-3024 Battery Charger(1) and five NiCad (Nickel Cadmium), Rechargeable Batteries, size AA. The batteries must be charged before using the 168-7720 Ultrasonic Wear Indicator III Group. Procedure 1. Move switch (1) on the rear of 4C-3024 Battery Charger(2) to the correct AC line voltage, either 120 V or 230 V, depending on use. 2. Connect charger connector (3) into the CHARGE connector located on the top of the Indicator III.
10
3. Plug power supply end (4) into an AC outlet. Note: For operation outside the USA, an AC power plug adapter may be required. 4. Turn the Indicator III ON to check if the batteries are being charged. It may be necessary to wait a few minutes until the batteries are sufficiently charged to operate the Indicator III. 5. When first turned ON, the display may flash, indicating low voltage. The flashing should stop after a few minutes as the batteries are charged. 6. Turn the Indicator III OFF and leave the charger ON for 10 to 14 hours. Note: The Indicator III will not be damaged if the charger is left on for longer time periods. Note: For maximum battery life, recharge only after the display flashes or goes blank, indicating the batteries are near or fully discharged. Replacing The Internal Rechargeable Batteries The 168-7721 Ultrasonic Wear Indicator III is supplied with five NiCad (Nickel Cadmium), rechargeable batteries (size AA). The batteries can be replaced with new 1U-7445 Batteries when the batteries no longer give sufficient operating time. The batteries can be replaced with 1U-9533 Alkaline Batteries (non-rechargeable). Note: The internal batteries can be removed indefinitely and the internal memory values will not be affected. NOTICE DO NOT attempt to recharge alkaline batteries using the 4C-3024 Battery Charger. Attempting to charge an alkaline battery can result in damage to the 168-7721 Ultrasonic Wear Indicator III. Place a piece of tape over the charge connector, to prevent charging, when using alkaline batteries.
Illustration 11
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Back View Of 168-7721 Ultrasonic Wear Indicator III
1. Remove two screws (1) from battery cover (2).
Illustration 12
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Indicator III With Battery Cover Removed
2. Remove battery cover (2). 3. Remove all batteries (3) and replace with new batteries.
Illustration 13
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Indicator III With Batteries Removed (4) + Or Positive Terminal
11
Connecting To DC power
Illustration 14
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Enlarged View Of Battery Compartment (4) + Or Positive Terminal
4. To install new batteries: The (+) terminal of the battery must be placed on the battery contact with the (+) symbol (4) (in the recessed area of the battery compartment, as shown in Figures 13 and 14 ).
The easiest way to install the batteries is to place the (-) terminal of one battery against one of the negative battery contacts (does not have (+) sign) inside of the battery compartment (5). Compress the negative battery contact as much as possible (see Figure 15 ) and then install the plus terminal (+) of the battery into the battery compartment.
156-1077 Power Inverter
(1) Power Inverter (2) Cigarette Lighter Adapter (3) Manual (4) Battery Power Clips Attached To Cable (5) Installed Fuse (6) Extra Fuses (7) Two Outlets That Accept The Power Cables Plug Supplied With The Emission Analyzer (8) ON/OFF Switch
1. The optional 156-1077 Power Inverter (12 VDC) may be used to connect the 168-7721 Indicator to an external DC power source. 2. Plug the power plug of the 4C-3024 Battery Charger into one of the two outlets on the 156-1077 Power Inverter. Refer to Figures 10 and 16. 3. When using the battery from a machine or engine as the power source, power the emission analyzer by connecting the power cable clip with the black colored handle to the machine or engines frame or to the battery negative terminal. Connect the power cable clip with the red colored handle to the battery positive terminal. NOTICE The 156-1077 Power Inverter requires a 12 VDC input. Make sure not to exceed this specification or the power inverter fuse may blow resulting in possible damage to the power inverter. Also, reverse polarity could damage the power inverter, but will most likely blow the 35 A fuse. Refer to item (5) Figure 11. 4. The 168-7721 Indicator can also be powered by a vehicles 12 VDC cigarette lighter. Remove the cable with the power clips from the power inverter. The power inverter can now be plugged into a cigarette lighter on a vehicle. Refer to Figure 16.
Illustration 15
g02901918
Installing Battery Cover
(5) Battery (-) Negative Terminal (6) Battery (+) Positive Terminal
5. Install battery cover (2) and replace two screws (1).
12
Care and Cleaning Of 168-7721Indicator III

The 168-7721 Ultrasonic Wear Indicator III is a durable hand held instrument. Since it will be used outdoors in a wide range of conditions, care must be taken to protect keep it clean. The case is water resistant, but not waterproof, and the instrument can be damaged if water is allowed to enter the case. If moisture does enter the case, the Indicator III should be allowed to dry out. Remove the rear cover and battery cover and allow to dry completely in a warm, dry area. Keep the Indicator III stored in the carrying case when not in use.
Turn the Indicator III ON

1. Press and release the ON/OFF key.
Illustration 17
g02901927
Copyright Display
Remove the 9U-7981Couplant Residue

When taking measurements, all excess 9U-7981 Couplant residue should be removed from the probe, Indicator III, and case with paper towels before the residue dries. The couplant is water soluble and a damp cloth can be used to remove any residue that has dried. Care must be taken so no water enters the Indicator III case.
2. The display will show the copyright display for a short time, then automatically change to a MACH (machine) display similar to those shown below.
Illustration 18
g02901936
Cleaning the Case and Front Panel Key Pad NOTICE DO not use aromatic hydrocarbons or chlorinated solvents for cleaning. These chemicals will react with the plastics used in the case and cause damage. Care of Connectors The RS232 and PROBE connectors, on the end of the Indicator III, must be kept clean. Allowing dirt to enter the contacts can cause interference and keep the mating connectors from plugging in or making proper contact. During use, the PROBE connector is protected by the probe cable connector. Leave the probe connected during storage so dirt does not enter. The RS232 connector is shipped with a plastic cap. Keep this cap in place at all times when this connector is not being used. Extra plastic caps are included with the group.
MACH Display (Memory Clear)
3. The MACH number (in the upper left-hand corner of the display) will be the one in use when the instrument was last turned OFF. If internal memory for the machine number shown is clear (contains no stored information), it will appear as the MACH display, as shown in Step 2.
Illustration 19
g02901957
MACH Display (Last Machine Used)
4. The example in Step 3, shows the MACH display with the model and serial (product identification) number of the last machine used shown. The MACH(ine) number may be selected with the up arrow or down arrow keys. Note: If the MACH(ine) number will not change: Press the LOC/MACH key to get to the MACH display as shown above. Then use the up arrow or down arrow keys again.
Operating Instructions for 168-7721Indicator III

Plug the connector on the end of the 168-7722 or 4C5485 Ultrasonic Probe Cable into the probe connector on the top of the Indicator III.
13
Calibrating the Indicator III Probe

Before taking measurements, the accuracy of the Indicator III and probe must be checked and the Indicator III and probe recalibrated, if needed. This procedure should be performed at the start of each day and anytime the accuracy is in question to ensure the readings taken will be accurate. Once the Indicator III and probe are calibrated with this procedure, it will ONLY be accurate for measuring undercarriage steel or steel of a similar type. If other materials are measured, the velocity must be changed and a different PROBE CAL value used. Refer to the Section Ultrasonic Velocity Adjustment in this manual.
Illustration 21
g02901962
Ultrasonic Wear Indicator III And Probe Being Calibrated
A metal calibration disk, Figure 21, is used to check the accuracy and calibrate the Indicator III and probe. 1. Place a small amount of 9U-7981 Couplant on the sensing end of the probe. See Figure 20. 2. Press the probe against the metal calibration disk on the top of the Indicator III. See Figure 21. 3. A number will appear at the MEASURED VALUE display. If the probe is properly coupled to the disk, the MM or IN indicator will also be displayed. Also, a beeping sound will be heard (if not turned OFF using the Settings menu) to indicate good coupling.
Applying Couplant To Ultrasonic Probe
Illustration 22
g02901963
Probe On Calibration Disk NOT In Calibration
Note: The thickness value and the units (0.25 IN) flash while the probe is coupled and the beeping sound occurs at the same rate. 4. The display value should be 6.3 mm (0.25 inch) when in the Low Resolution Mode. If not correct as shown in Step 3, follow the instructions in Step 6.
14
Undercarriage Measurement Procedure

Note: When using this procedure, refer to the Section Undercarriage Measurement Display Map in this manual, for additional information on the sequence of the displays. 1. The Indicator III MUST be calibrated before any measurements are taken. Refer to the Section Calibrating the Indicator III Probe. 2. After calibration, use the up or down arrow keys to select a (CLEAR) machine or to locate the specific machine you are measuring.
Illustration 23
g02901964
Probe Removed From Calibration Disk
5. If the calibration is correct, as shown in Step 4, proceed to the Section Undercarriage Measurement Procedure. 6. To calibrate the Indicator III and probe, press the PROBE CAL key. The display should now show (PROBE).
Clearing The Memory

1. If a (CLEAR) machine cannot be located, any one or all machines can be cleared by first pressing and releasing the red SHIFT key and then pressing CLR MACH key.
Illustration 24
g02901967
PROBE CAL Key Pressed
7. Place a small amount of the 9U-7981 Couplant on the sensing end of the probe. Press the probe to the metal calibration disk. See Figure 21.
Illustration 26
g02901974
2. Press the Value key to clear one machine (Machine 2 in this example).
Illustration 25
g02901970 Illustration 27 g02901975
Calibration Complete
Display While One Machine Is Being Cleared
8. The MEASURED VALUE, shown in Step 7, should now be correct. If not, repeat this procedure until correct. 9. Once the correct value appears, the wear indicator is ready to use. Note: An alternate method of calibration is to press the PROBE CAL key while holding the probe on the disk. If the Indicator III still will not calibrate correctly, check for the proper velocity setting for undercarriage steel. Refer to the Section Ultrasonic Velocity Adjustment in this manual.
3. The message shown above will appear on the display for a short time. The (CLEAR) message indicates the memory has been cleared and is ready for a new data. 4. To clear all machines, first press the up or down arrow key to move the cursor to the bottom line of the display, which shows CLR ALL MACH. Press the VALUE key.
15
(Table 5, contd) 9 IMPACT COND The underfoot Conditions - Impact, use SET DIGIT: MODERATE, HIGH, LOW The underfoot Conditions - Abrasive, use SET DIGIT: MODERATE, HIGH, LOW The underfoot Conditions - Moisture, use SET DIGIT: MODERATE, HIGH, LOW
10
ABRASIVE COND MOISTURE COND
11
Display While All Machines Are Being Cleared
5. The display will then be replaced with the (CLEAR) message indicating the memory has been cleared and is ready for new data.
11
PACKING COND The underfoot Conditions - Packing, use SET DIGIT: MODERATE, HIGH, LOW BUSHING ALLOW L TRACK SAG L DRY JOINTS L LINK L BUSH INT Bushing allowable wear, use SET DIGIT: GREATER, LESSER Left track sag- use SET DIGIT Left Dry joints - use SET DIGIT Left link measurement Left bushing internal wear use - SET DIGIT
13
Using LOC(ation) Mode of Operation

To store ultrasonic measurements and input information about the machine being measured, the Indicator III must be in the LOC(ation) mode operation. To change to the LOC(ation) mode from the MACH (ine) mode, press the LOC/MACH key. This key always changes the display to the other mode of operation. If the word MACH is not on the display, the Indicator III is in the LOC(ation) mode. Once in the LOC(ation) mode, the 71 different undercarriage storage locations shown in Table 5, List of Undercarriage Storage LOC(ation) Displays are available for use. These storage locations can be accessed with the up and down arrow keys. Refer to the Section Undercarriage Measurement Display Map in this manual for additional information on how to change between the various displays. List of Undercarriage Storage LOC(ation) Displays
24 Table 5 Loc. 1 2 3 Display MODEL SERIAL NUMBER DATE MM/DD/ YYYY DATE DD/MM/ YYYY HOURS HRS/WEEK MILES KM MILES/WEEK KM/WEEK JOB SITE Notes The machine model number The machine serial number The date by month, day, year The date by day, month, year 25 26 27 28 29 30 The service hour meter reading on the machine The number of hours the machine has worked per week The reading on the machines odometer in miles or kilometers The distance the machine has traveled per week The location of the machine 31 32 33 34 35 36 37 38 39 (continued) 14 15 16 17 18 19
L BUSHING EXT Left bushing external wear BUSHING TOOL Measuring tool used on bushings (EXT). SET DIGIT: ULTRASONIC, CALIPER, DEPTH GAUGE L SHOE SHOE TOOL Left shoe measurement Measurement tool used on shoes. SET DIGIT: ULTRASONIC, DEPTH GAUGE
20 21
22 23
F IDLER DEPTH Front idler depth gauge measurement - use SET DIGIT F IDLER SONIC Front idler ultrasonic measurement use SET DIGIT
R IDLER DEPTH Rear idler depth gauge meas. R IDLER SONIC L CAR. ROLL 1 L CAR. ROLL 2 L CAR. ROLL 3 CAR. ROLL TOOL L ROLLER 1 L ROLLER 2 L ROLLER 3 L ROLLER 4 L ROLLER 5 L ROLLER 6 L ROLLER 7 L ROLLER 8 L ROLLER 9 L ROLLER 10 Rear idler ultrasonic measurement Left carrier roller number 1 Left carrier roller number 2 Left carrier roller number 3 Measuring tool used on carrier rollers. SET DIGIT: ULTRASONIC, CALIPER Left track roller number 1 Left track roller number 2 Left track roller number 3 Left track roller number 4 Left track roller number 5 Left track roller number 6 Left track roller number 7 Left track roller number 8 Left track roller number 9 Left track roller number 10
4 5 6 7 8
(continued)
16
(Table 5, contd) 40 ROLLER TOOL Measuring tool used on track rollers. SET DIGIT: ULTRASONIC, CALIPER, DEPTH GAUGE Left sprocket - use SET DIGIT Right track sag - use SET DIGIT Right dry joints - use SET DIGIT Right link measurement Right bushing internal wear- use SET DIGIT
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71
L SPROCKET R TRACK SAG R DRY JOINTS A LINK A BUSHING INT
MODEL Display With Empty MODEL Number
A BUSHING EXT Right bushing external wear R SHOE Right shoe measurement
F IDLER DEPTH Front idler depth gauge measurement - use SET DIGIT F IDLER SONIC Front idler ultrasonic measurement
R IDLER DEPTH Rear idler depth gauge measurement - use SET DIGIT R IDLER SONIC A CAR. ROLL 1 A CAR. ROLL 2 A CAR. ROLL 3 A ROLLER 1 A ROLLER 2 A ROLLER 3 A ROLLER 4 A ROLLER 5 A ROLLER 6 A ROLLER 7 A ROLLER 8 A ROLLER 9 A ROLLER 10 R SPROCKET NOTES LINE 1 NOTES LINE 2 NOTES LINE 3 NOTES LINE 4 SPARE # 1 SPARE # 2 Rear idler ultrasonic measurement Right carrier roller number 1 Right carrier roller number 2 Right carrier roller number 3 Right track roller number 1 Right track roller number 2 Right track roller number 3 Right track roller number 4 Right track roller number 5 Right track roller number 6 Right track roller number 7 Right track roller number 8 Right track roller number 9 Right track roller number 10 Right sprocket - use SET DIGIT 16 characters - use SET DIGIT 16 characters - use SET DIGIT 16 characters - use SET DIGIT 16 characters - use SET DIGIT For extra measurement For extra measurement
MODEL Display Containing MODEL Number
The first storage location is MODEL. This display is shown above in the way it appears with and without a model number in memory. The machine model number can be entered where the dotted line is or a number already shown can be changed. This display will always be the first display shown when switching from the MACH(ine) or LOC(ation) mode of operation.
Entering Information into the Indicator III

If the memory contains a MODEL number, the model number will always be shown on the display. If memory does not contain a MODEL number, dashed lines will show where the model number should be entered. To enter the MODEL, press the VALUE key and the first number digit location will become a blinking box. Whenever a blinking box is on the display, numbers or alphabetical characters may be entered directly using the keys on the front panel. To enter the red characters, the red SHIFT key must be pressed and released before the character key is pressed. To enter a blue character, the blue SHIFT key must be pressed and released before the character key is pressed. Continue this procedure until the entire MODEL number is on the display. When finished, press the SAVE key and the MODEL number will be stored in memory. After SAVE is pressed, the Indicator III will advance the display to the next LOC(ation) display, which is the SERIAL NUMBER.
Note: The Setting Menu is used to change how the Date (location 3), the Distance (location 6), and the Distance per Week (location 7) are displayed.
17
To enter the serial (product identification) number into the SERIAL NUMBER display, follow the same procedure as used in the Section Using LOC(ation) Mode of Operation. Up to 16 numbers or letters in any combination can be entered as the serial number on the blanks provided. If the serial number does not fill all the blanks, the serial number will be moved to the right of the display when saved. The same procedure will be used for entering: DATE HOURS HRS. PER WEEK MILES or KM MILES PER WEEK or KM PER WEEK JOB SITE, and
On these displays, alternate words are available. To view the other words available, press the VALUE key. The other words will appear, as shown in the previous examples. To select and store the desired word in the memory, leave in the display and press the up arrow key to move on to the next location. The selected word will always reappear in the display when that display is used again.
Measuring Track Sag

The first display for a measurement is L TRACK SAG (left track sag). This measurement cannot be taken with the Indicator III.The measurement must be taken according to the instructions in the CTS handbook with a tape measure and manually entered into the III memory. 1. To enter this measurement at the L TRACK SAG display, press the VALUE key. 2. The first digit of the MEMORY VALUE will flash, allowing the measurement to be entered. Refer to the Section Entering Information into the Indicator III. 3. When the proper number has been entered, press the SAVE key to continue with the next reading.
Changing Displays with Words

The LOC(ation) displays for underfoot conditions (IMPACT), bushing allowable wear (BUSHING ALLOW), and measurement tool used (BUSHING TOOL or SHOE TOOL) have words in them.
Taking Ultrasonic Measurements

The next LOC(ation) is L LINK (left link measurement) and is the first measurement to be taken with the ultrasonic probe. Note: Refer to the Section Undercarriage Measurement Techniques, in this manual, for details on how to measure each undercarriage component. 1. To take a measurement, place a small amount of 9U-7981 Couplant on the sensing end of the probe and press firmly and squarely against the wear surface. 2. The measurement will appear on the display above MEASURED VALUE. 3. An indication of proper coupling of the probe is shown by IN or MM appearing after the MEASURED VALUE. Also, a beeping sound will be heard (if not turned OFF using the Settings menu) to indicate good coupling. Note: The thickness value and its units (4.92 IN) flash while the probe is coupled and the beeping sound occurs at the same rate. 4. When you are satisfied a good value is on the display, remove the probe and that value will remain in the MEASURED VALUE display.
Illustration 31
g02902042
Example Of IMPACT With Alternate Word MODERATE
Illustration 32
g02902043
Example Of IMPACT With Alternate Word HIGH
Example Of IMPACT With Alternate word LOW
Note: Measurements can only be taken in the MACH (ine) Display Mode or in LOC(ation) Display Modes screen that accepts ultrasonic measurements.
18
Saving Measured Values in Memory

The measured value shown on the display can be saved in the memory of the wear indicator by pressing the SAVE key. After a (SAVE) indication has flashed on the display, the next undercarriage part to be measured will automatically appear on the display. To make sure that the number was recorded correctly, press the down arrow key to go back to the previous LOCATION. The value measured will show on the MEMORY VALUE display. Note: While taking an ultrasonic measurement, once satisfied of a good measurement, press the SAVE key before removing the probe.
Pressing the VALUE key will select CALIPER or DEPTH GAUGE. Select the tool to be used and then press the up arrow key to move to the next display and the selected tool will be put in memory. Continue through the LOCATION displays until all of the undercarriage measurements have been taken and recorded. Spaces for notes and two extra measurement storage locations have been provided at the end of the measurement sequence. When finished with the measurements, advance to the next machine by pressing LOC/MACH and the up arrow key.
Tool Displays
Some displays refer to the type of tool used for measurement of the component described. If a tool other than the ultrasonic is used to measure the component, the correct tool must be selected. This is needed to indicate which wear charts should be used. An example is the BUSHING TOOL display as shown below:
Measurement Operating Tips

The following operating tips will make it easier to take measurements with the Indicator III. 1. The sequence of the undercarriage storage locations were selected to transfer into the Custom Track Service personal computer program. Until you have this program, it may save time to enter and save only the serial number and measurements in the indicator III. Then manually record the data for locations 2 through 13 directly on the CTS Form. Refer to the Section General Information. After taking measurements, scroll through the stored measurements while manually recording them on the CTS form. 2. When using the arrow keys, press and release the keys to change the display slowly, or hold the key down to scroll rapidly. 3. For users preferring not to use the memory feature, ultrasonic measurements can be taken at any time regardless of the LOC(ation) or MACH(ine) settings. When taking measurements, the 9U-7981 Couplant must be applied to the sensing end of the probe before measuring component. 4. To couple the ultrasonic probe to a component, it is important to have the 9U-7981 Couplant between the sensing end of the probe and the component. The probe tip surface must be flat (square) with the part being measured. It may be easier to hold the probe properly if a finger is held on top of the probe. 5. When taking ultrasonic measurements, keep in mind the first reading displayed may not be the best measurement. Always move the probe around the part surface to find the smallest, or most worn measurement. 6. Saving ultrasonic measurements can be done either while holding the probe on the part or after removing the probe. If you prefer to remove the probe before pressing SAVE , pull off the probe quickly to prevent the measurement from increasing slightly as the probe is removed.
Illustration 34
g02902121
Example of BUSHING TOOL with type of tool used: ULTRASONIC
Illustration 35
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Example of BUSHING TOOL with type of tool used: CALIPER
Illustration 36
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Example of BUSHING TOOL with type of tool used: DEPTH GAUGE
19
Undercarriage Measurement Techniques

Track Links
Illustration 39
g02902176
Probe Located On The Tip Of The Grouser
2. It may be easier to measure from the tip of the grouser to the bottom of the plate.
Measuring Track Links
3. On double grouser and triple grouser shoes, do not measure the rear grouser due to interference with the trailing edge. 4. On regrousered shoes, it may be necessary to use a depth gauge or take ultrasonic measurements from the tip and the bottom of the plate and add the readings together, since the weld does not completely penetrate.
1. Measure distance from tread surface to bushing bore. 2. Place probe over the center line of the bushing. 3. Slide the probe along the tread surface and take the smallest reading.
Track Bushing
Track Shoes
Illustration 40 Illustration 38 g02902164
g02902196
Probe Located On The Bottom Of The Plate
1. Measure the wall thickness. 2. Slowly slide the probe around the reverse drive side to find the smallest dimension and save this measurement. 3. Next, slide the probe around the vertical and forward drive sides to check if the measurement is smaller (indicating more worn). Always save the smallest measurement.
1. Measure the distance from the bottom of the plate to tip of the grouser.
20
Idler
Illustration 43 Illustration 41 g02902201
g02902204
1. Measure the center flange thickness only on fabricated idlers. Determine center flange wear from the idler wear charts in the CTS Handbook. 2. Use conventional depth gauge to measure wear on the tread surface. 3. Add center flange wear to the depth gauge, measurement before determining percent worn.
Carrier Roller
Three Piece Rims
Measure Distance From The Outside Of Tread Surface To The Bore
Note: Due to the use of tapered roller bearings, more than one thickness can be found along each tread surface. It is important to place the probe on the outer half of the tread surface on the side of the roller opposite the shaft. Note: The Ultrasonic Wear Indicator III will not measure cast iron rollers. Some D3, D4, D5, and D6 Tractors or 225 Excavator carrier rollers are cast iron.
Illustration 42
g02902205
Measure the Thickness Of Press-On Rim
21
Track Roller
Note: In addition to measuring steel parts, many other materials can be measured. However, to accurately measure these materials, the velocity setting of the Indicator III must be changed. Refer to the Section Ultrasonic Velocity Adjustment in this manual for complete information other than steel. 1. Install 168-7722 or 4C-5485 Probe, and calibrate the Indicator III and probe. Refer to the Section Ultrasonic Velocity Adjustment in this manual. When taking measurements, the 9U-7981 Couplant must be applied to the sensing end of the probe before measuring. 2. To take a reading, apply a small amount of couplant on the sensing end of the probe and press the probe onto the surface to be measured. The thickness of the material will be shown at MEASURED VALUE on the display. Whenever the probe is properly coupled, either IN or MM will show on the display. Also, a steady beeping sound will be heard (if not turned OFF in the Settings Menu). When the probe is removed from the material, the last reading will remain on the display. 3. To check the accuracy of the reading, measure a piece of the same type of material of known thickness. If the reading is not correct, the velocity may be adjusted to make the Indicator III read accurate. Refer to the Section Ultrasonic Velocity Adjustment in this manual.
Illustration 45
g02902237
1. Measure the distance from the tread surface to the bore. 2. Do not measure to the retainer bolt holes on H, N, and L series Track-Type Tractors and current Track-Type Loaders. Observe the location of the retainer bolts and place the probe between them. On low sprocket Track-Type Tractors, earlier Type Loaders, and Excavators the retainer bolts are not visible. Observe the thickness measured value closely from roller to catch any abnormally small thickness which would indicate a reading to the bolt hole. 3. On track rollers with noticeable cusp wear, slide the probe along the cusp to get the smallest readings. To speed the process, select the cusp that normally is most worn (the cusp closer to the center of the roller), rather than sliding the probe over both cusps each time.
Transferring the Memory Values To or From a Computer

The information contained (saved) in the Indicator III memory may be transferred to an IBM or compatible personal computer for storage or printing using the Custom Track Service (CTS) personal computer program. When transferring machine data from an IBM or compatible personal computer using the Custom Track Service (CTS) program: 1. The Indicator III does not clear all 64 machines before transferring new machine data from the PC. The CLR ALL MACH function may be used to manually clear all 64 machines. 2. The user can select where the machine data will be stored in the Indicator III by scrolling to the Machine No. before the transfer. The Indicator III will then store the transferred data from the machines beginning with the MACH(ine) No. shown on the Indicator III display. Note: One exception is if there is no MACH(ine) data stored in the Indicator III before the transfer, then a transfer from the PC to the Indicator III will result in the new machine data being stored beginning with the Machine No. 1 instead of the MACH(ine) No. currently shown on the screen.
Competitive Parts
Do not measure competitive undercarriages with the indicator III. The internal dimensions of these parts will likely be different than on the Cat designed parts, resulting in incorrect percent worn readings.
Measuring the Thickness of Parts Other than Undercarriage

In addition to measuring undercarriage wear, the Ultrasonic Wear Indicator III can be used to measure steel part thickness without changing any settings. This is simple to do because the wear indicator is designed to show the MEASURED VALUE regardless of which keys have been pressed. This allows a nonexperienced person to take readings. Examples where this may be used to check the wall thickness of a: Bulldozer blade Bucket base edge Scraper bowl
22
Note: When transferring machine data from a PC to the Indicator III, the Indicator III does not wrap around the 64 MACH(ine) locations. The data from three machines is transferred from the PC, MACH(ine) memory in the Indicator III is not empty, and the Indicator III displays MACH(ine) 63. The first machine transferred will be stored in MACH(ine) 63, the second machine transferred will be stored in MACH(ine) 64, and the third machine will overwrite the second machine and be stored n MACH(ine) 64.
23
Settings Menu
Illustration 46
24
g02902257
Settings Menu Operation (Default States Shown)
25
Illustration 47
g02902259
Settings Menu Operation
26
The Settings Menu is a special menu to change specific functions for the wear indicator. Enter the Settings Menu by pressing and releasing the blue SHIFT key and then pressing the SAVE/SET key. The Settings Menu flow chart is shown as Figure 46. The Settings Menu contains these functions in this order: Resolution, Turnoff, Velocity, Serial, Beeper, Language, Distance, and Date. Resolution is the first function displayed when entering the Settings Menu. Press the up down arrow to scroll forward through the Settings Menu or up arrow to scroll backwards through the Settings Menu. Figure 47 shows the different settings that can be selected with each function in the Settings Menu.
Beeper
This function turns ON or OFF the beeper that sounds when the probe is properly coupled to the material being measured. When turned OFF, coupling will still be indicated any MM or IN being displayed beside the MEASURED VALUE when properly coupled. 1. ON (default position). 2. OFF.
Language
This function allows the language to be changed. All of these languages are in the 168-7721 Ultrasonic Wear Indicator III and are selectable. 1. ENGLISH (default position). 2. FRENCH. 3. GERMAN. 4. PORTUGUESE. 5. SPANISH.
Resolution
Allows the measurement resolution to be in a high or a low mode. 1. Low Resolution mode (default position) is 0.0 mm (0.00 inch). 2. High Resolution mode is 0.00 mm (0.000 inch)
Turnoff
This function allows for longer battery life by automatically turning the Indicator III OFF if it has not been used for 5 minutes. Normal operation of the key pad ON/OFF switch is not affected. 1. MANUAL - Indicator III only turns OFF by using the ON/OFF key switch. 2. AUTO (default position) - Indicator III automatically turns off after 5 minutes and no keys have been pressed or the probe has not been coupled. The Indicator III will also turn off by using the ON/OFF key switch.
Distance
Allows the units for distance to be changed: 1. MILES (default position). 2. KM - Kilometers.
Date
This function allows date configuration to be selected: 1. MM/DD/YYYY - Month, Day, Year (default position). 2. DD/MM/YYYY - Day, Month, and Year.
Velocity
Allows the ultrasonic velocity to be viewed on the display and changed using the front panel key pad. 1. OFF - Velocity adjust disabled (default position). 2. ON - Velocity adjust enabled.
Ultrasonic Velocity Adjustment

Adjustment of the velocity calibrates the Indicator III so it can be used accurately to measure the thickness of materials other than undercarriage steel. Ultrasonic Velocity is the speed in Millimeters per microsecond (MM/uSEC) or inches per microsecond (IN/uSEC) that sound travels through different materials. Refer to Table 6 for a list of various materials, ultrasonic velocities, and probe calibration values.
Serial
This function controls the speed (BAUD Rate) of the RS232 communications signal of transferring memory values from the 168-7721 Ultrasonic Wear Indicator III to a personal computer with Custom Track Service software program installed or transferring the memory values back to the Indicator III. The different BAUD rates that are available are: 1. 1200. 2. 9600 (default position). 3. 19200.
27
Table 6 Material Velocity MM/uSEC (IN/uSEC) 6.09 mm (0.240 inch) 4.57 mm (0.180 inch) 4.57 mm (0.180 inch) 5.33 mm (0.210 inch) 5.84 mm (0.230 inch) 2.67 mm (0.105 inch) 5.84 mm (0.230 inch) 3.30 mm (0.130 inch) 5.87 mm (0.231 inch) Probe CAL1 Measured Value 6.3 mm (0.25 inch) 4.8 mm (0.19 inch)
Aluminum Cast Iron Copper Glass Mild Steel Plastic (Plexiglass) Stainless Steel Tin Undercarriage Steel
1
4.8 mm (0.19 inch) 5.6 mm (0.22 inch) 6.3 mm (0.25 inch) 2.8 mm (0.11 inch) 6.3 mm (0.25 inch) 3.6 mm (0.14 inch) 6.3 mm (0.25 inch)
Example of Screen Display with VEL in IN/uSEC
3. If the Indicator III is being used to measure Undercarriage Steel, be sure that it reads 5.87 MM/ uSEC or (.231 IN/uSEC), as shown in Step 2. If the number is not correct, or you plan to measure other materials, the velocity number can be changed. Refer to the Section Changing the Ultrasonic Velocity.
Changing the Ultrasonic Velocity

1. Locate the velocity number for the material to be measured in Table 6. The numbers given in Table 6 are approximate, and slightly different numbers may need to be used to give accurate readings because of differences in material composition. 2. With the display showing the velocity, as shown in Step 2 in Checking the Ultrasonic Velocity, press the VALUE key. The first digit of the velocity number will flash. Use the number keys to set the velocity to the desired number 3. When the desired velocity number is shown on the display, press the SAVE key and the Indicator III will now be set for the new material. 4. Calibrate the probe for this new material by pressing the PROBE CAL key. Then place the probe, with couplant applied to the sensing end of the probe, on the calibration disk. The number shown as the MEASURED VALUE on the display should be the value shown on the Velocity Table under PROBE CAL. MEASURED VALUE for the new material. Every time the calibration disk is measured with this new velocity setting, this reading should appear on the MEASURED VALUE display instead of 6.3 mm (0.25 inch). 5. Measure a known thickness of the new material with the Indicator III to be sure that the readings are accurate. 6. If the readings are not exact, change the velocity setting number right-hand digit by one and recalibrate.
This is the value that will show at MEASURED VALUE on the display when the metal calibration disk is measured for each velocity listed.
Checking the Ultrasonic Velocity

1. Enter the Settings Menu and change the VELOCITY from OFF to ON (refer to the Section Settings Menu). 2. With the Indicator III ON, make sure that display is in the MACH(ine) display mode, then press the MM/INCH key. The velocity setting of the Indicator III will appear on the bottom line of the display, as shown below. Either MM or IN will be displayed, depending on which was being used earlier.
Illustration 48
g02903197
Example of Screen Display with VEL in MM/uSEC
7. Measure the material again and continue this process until the Indicator III reads correctly.
28
Battery Level Monitor

A Battery Level Monitor displays the estimated battery power remaining. Since many factors influence the discharge rate, the battery level monitor is only an estimate of the remaining battery life and should only be used as an estimate. The Battery Level Monitor will show a percent value ranging from 0% to 100% in 10% increments. Monitor shows 100% when the battery voltage is greater than or equal to 6.0 V. A value of 0% will be displayed anytime the battery voltage falls to 5.4 V or less. The Battery Level Monitor screen will appear as follows:
Return to Last Menu Screen

The Indicator III will remember the last MACH(ine) or LOC(ation) Display Mode screen that was displayed when the Indicator III was last turned OFF. If the Indicator III was turned OFF in the Settings Menu or showing the Battery Level Monitor screen, then it will display the last MACH(ine) or LOC(ation) Display Mode screen when the Indicator III was last powered up. The Machine or Location Display Mode screen will not be remembered if a factory reset was performed or if the Indicator III was abnormally powered down. For example, by pulling out batteries while the Indicator III is ON.
Factory Reset
This function will reset the Indicator III back to the state it was in when it left the factory. The reset will destroy all stored data and completely reset all parameters in the Settings Menu to the default states. To reset, the Indicator III must be OFF. Then, press and hold the CLR and ON/OFF keys at the same time for at least 3 seconds. The Indicator III will turn ON and will display "FACTORY RESET while the factory reset is being performed.
Illustration 50
g02903199
Note: If using NiCad rechargeable batteries, the batteries must be fully charged before each use for the Battery Level Monitor to work correctly. Refer to the Section Charging the Internal NiCad (rechargeable) Batteries.
Viewing the Software Version Screen

The version number of the software used in the Ultrasonic Wear Indicator III can be viewed on the display in the following manner. 1. Turn the Indicator III OFF. 2. Press and hold the LOC/MACH key, then press ON/OFF to turn the Indicator III ON.
Low Battery Indication

The LCD display will flash for at least 30 seconds when the battery voltage reaches 6.14 V, which is when a minimum of 2 hours of battery life is left. It will then stop flashing for about 30 minutes and return to at least a 30 second flashing period. When the Indicator III has reached a minimum of 1 hour of remaining battery life, the display will flash and continue to flash until the power is increased by charging the NiCad batteries or installing new alkaline batteries. The Indicator III shuts down when the battery voltage reaches approximately 5.12 V. Note: If using NiCad rechargeable batteries, the batteries must be fully charged before each use for the Low Battery Indication to work correctly. Refer to the Section Charging the Internal NiCad (rechargeable) Batteries. Note: When the probe is coupled and the Indicator III battery power is low, the beeping sound will be heard at half rate. The beeping sound occurs when the entire display flashes during a low battery indication.
Illustration 51
g02903200
Example of Screen Display For SOFTWARE VERSION Number
3. When the Indicator III comes ON, the Software Version screen is displayed, as shown in Step 2. To leave this screen, turn the Indicator III OFF. The software is the program that operates the microprocessor in the Indicator III. It is contained nonvolatile, located in the Indicator III, so removing the batteries for an indefinite time will not affect the memory.
29
Checking the Operation of the Indicator III

The following procedure may be used to check the operation of the 168-7721 Ultrasonic Wear Indicator III and the 168-7722 and 4C-5485 Probe. The only components required for the test are the 168-7721 Ultrasonic Wear Indicator III, 168-7722 and 4C-5485 Probe, and 9U-7981 Couplant. Perform all the procedures, as shown in the Section Operating Instructions for 168-7721Indicator III, in this manual. Instead of measuring undercarriage components, the metal calibration disk should be measured and the MEASURED VALUE saved, and the MEMORY VALUE displayed to check for accurate readings. Alternate Method An alternate method is to measure a known thickness of undercarriage steel. 1. Check the display of the undercarriage storage locations for one machine. During this test, use all front panel keys to be sure that the panel keys operate correctly. If the Indicator III does not operate properly during this test, refer to the Section Troubleshooting in this manual. 2. Next, test the Indicator III on actual undercarriage components. Correct measurements should appear on the MEASURED VALUE display without having to move the probe back and forth. 3. Also check to see that measurements can be taken on thick undercarriage components such as through track shoe grouser bars. 4. If the Indicator III has trouble making any of these readings, the gain may need to be adjusted. Refer to the Section Troubleshooting in this manual for the procedures to adjust the gain. 5. This completes the test of the Indicator III.
Cover Removed To Access The Gain And Display Contrast adjustments
(1) RP1 Gain Adjustment (2) RP2 Display Contrast Adjustment
2. Locate contrast adjustment, Figure 52 on the top of the printed circuit board. It is one of only two screwdriver adjustments and is located below the calibration block and is labeled RP2 on the printed circuit board. 3. Before turning this adjustment, observe the position of the screwdriver slot to see if it is marked. Place a mark on the small plastic case if the position is not already marked. This is the factory setting of the display contrast. Marking this position will allow you to return it to its original setting, if desired. 4. To adjust the display contrast, use a small flat head screwdriver to turn the contrast while viewing the display screen. Continue to adjust until the information on the screen is clear to the user preference. Once the setting is obtained, replace the rear cover.
Adjusting the Display Contrast

The display contrast may be adjusted to the users preference. The contrast has been set at the factory. If the contrast needs to be changed, use the following procedures: 1. Remove six screws from the back cover and remove the cover.
Adjusting the Gain

If the gain is out of adjustment, it will result in inaccurate or hard to get readings, or no echo. If the gain needs to be changed, use the following procedures: Note: The gain adjustment is set at the factory using precision instruments and should not be changed unless necessary. 1. Remove six screws from the back cover and remove the cover. 2. Locate gain adjustment, Figure 52, on the top of the printed circuit board.
30
3. Before turning this adjustment, check and see if the position is marked. If not marked, place a mark on the small plastic case. This is the factory setting of the gain adjustment which was set using instruments. Marking this position will allow you to return to original setting if you have trouble with the operation of the Indicator III during this procedure. 4. Make sure that the beeper is ON, which is selected as ON or OFF in the Settings menu. 5. To adjust the gain, use a small flathead screwdriver to turn the gain adjustment while measuring a thick undercarriage component, such as a large track roller or shoe grouser. a. Turning the adjustment clockwise, right, decreases the gain until no echo is received. No beeping sound heard and no measurement taken. b. Turning the adjustment counterclockwise, left, increases the gain. Note: If the gain is increased too much, the beeper will not turn OFF when the probe is removed from the component being measured. c. The correct setting is when the gain control is set to the most counterclockwise position that will allow readings to be taken easily, and the beeping stops when the probe is removed. It may take some trial and error and trying various component measurements before the best setting is obtained. 6. Once this setting is obtained, replace the rear cover.
If you have another probe that is known to be good, try it and see if it works. If not, use the following procedures: 1. Take the Indicator III to a quiet place. 2. Put the probe close to your ear. 3. Turn the Indicator III ON. 4. You should hear a high frequency sound emitted by the probe. 5. Remove the probe cable connector from the Indicator III and turn it around in the PROBE connector so the tab is at the rear of the Indicator III. The cable connector will not fit completely against the connector panel, but will still make contact. Again, with the Indicator III ON, you should hear the sound emitted by the probe. If you do not hear the sound both times, the probe has failed and must be replaced. 6. Sometimes the crosstalk barrier (between the two halves on the face of the probe) becomes worn or saturated with couplant. This can result in bad readings or readings while not measuring any material. If this problem occurs, try adjusting the gain of the Indicator III. If this fails to correct the problem, replace the probe.
Undercarriage Measurement Display Map

Note: Settings menu in default states.
Troubleshooting
If the Indicator III does not operate properly, first check the Battery Level Monitor to see if the batteries have sufficient power remaining. If not, and NiCad batteries are installed, then recharge or replace with new alkaline batteries. As the rechargeable batteries age, they will provide less operating time for the Indicator III. When the operating time between charging is unacceptable, the batteries should be replaced with new NiCad batteries. Note: The longest life will be obtained by charging the batteries only after the display is flashing, indicating the batteries are fully or near being discharged. If the Battery Level Monitor shows that the batteries have sufficient power remaining and the Indicator III still will not turn ON, it must be sent in for repair. Refer to the Section Service in this manual. If the display comes on but the Indicator III will not take measurements, the problem may be in the probe.
31
Illustration 53
g02903202
32
Location Display Map

Note: Settings menu in default states and units are inches.
33
Illustration 54
g02903203
34
Illustration 55
g02903204
35
9U-7981Couplant Material Safety Data Sheet

(To comply with 29 CFR 1910, 1200) Effective Date: 2/98 N/A = not applicable or not available Section 1 - Product Identification
Illustration 59
g02903208
Section 5 - Reactivity Data
Illustration 56
g02903205
Section 2 - Hazardous Ingredients
Illustration 60
g02903209
Section 6 - Health Hazard and First Aid Data

Section 3 - Physical Data (nominal)
Illustration 61
g02903210
Section 7 - Storage and Handling Information

Section 4 - Fire and Explosion Hazard Data
36
Illustration 62
g02903211
Section 8 - Control Measures
Illustration 63
g02903212
Service
If the Ultrasonic Wear Indicator III does not operate correctly, recharge or replace the internal NiCad batteries with new ones and check the operation. If it still does not operate, refer to the Section Troubleshooting in this manual. If the Indicator III is found to be faulty, contact Dealer Service Tools for information on how to obtain the needed repair service. Dealer Service Tools provides the instrument user with a warranty of 1 year from purchase date. If the reason for failure is determined to be abuse, the warranty is declared void. Any out-of-warranty repairs will be charged to the owner.
37
2013 Caterpillar All Rights Reserved
CAT, CATERPILLAR, their respective logos, Caterpillar Yellow, and the POWER EDGE trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

NEHS0730-03 Tool Operating Manual 168-7720 Ultrasonic Wear IndicatorIII Group

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NEHS0730-03 Tool Operating Manual 168-7720 Ultrasonic Wear IndicatorIII Group

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NEHS0730-03 11 September 2013

Tool Operating Manual

168-7720 Ultrasonic Wear Indicator III Group

Caterpillar Products All

Prohibited Action No smoking

General Information Section

Crushing hazard (hand)

Electrical Shock - Hazard

Service Parts Section

Safety Icon Nomenclature

168-7721 Ultrasonic Wear Indicator III

Personal Protection/Important Information

Additional Contact Information

Other Uses for The Indicator III

General Measurement Benefits

Benefits Ultrasonic Wear Indicator III

Undercarriage Measurement Benefits

Storage Of Conventional Tools

168-7720Ultrasonic Wear Indicator III Group

Part No. PEKP9400 5P-3277 8H-8580 5P-8616 5P-8617 6V-9410 5P-3920

(4) (5) (6)

1U-7445 1U-9533 156-1077

168-7720Ultrasonic Wear Indicator III Group Specifications

168-7722Ultrasonic Probe Specifications

156-1077Power Inverter Specifications

Connections to the 168-7721Indicator III

168-7721Indicator III Description

168-7721 Indicator III Front Panel And Key Pad

Charging the Internal NiCad (rechargeable) Batteries

Rear View Of 4C-3024 Battery Charger

Back View Of 168-7721 Ultrasonic Wear Indicator III

1. Remove two screws (1) from battery cover (2).

Indicator III With Battery Cover Removed

Indicator III With Batteries Removed (4) + Or Positive Terminal

Enlarged View Of Battery Compartment (4) + Or Positive Terminal

156-1077 Power Inverter

Installing Battery Cover

5. Install battery cover (2) and replace two screws (1).

Care and Cleaning Of 168-7721Indicator III

Turn the Indicator III ON

Remove the 9U-7981Couplant Residue

MACH Display (Memory Clear)

MACH Display (Last Machine Used)

Operating Instructions for 168-7721Indicator III

Calibrating the Indicator III Probe

Ultrasonic Wear Indicator III And Probe Being Calibrated

Applying Couplant To Ultrasonic Probe

Probe On Calibration Disk NOT In Calibration

Undercarriage Measurement Procedure

Probe Removed From Calibration Disk

Clearing The Memory

PROBE CAL Key Pressed

g02901970 Illustration 27 g02901975

Display While One Machine Is Being Cleared

ABRASIVE COND MOISTURE COND

Display While All Machines Are Being Cleared

Using LOC(ation) Mode of Operation

L SPROCKET R TRACK SAG R DRY JOINTS A LINK A BUSHING INT

MODEL Display With Empty MODEL Number

MODEL Display Containing MODEL Number

Entering Information into the Indicator III

Measuring Track Sag

Changing Displays with Words