NEHS0730-02 - Ultrasonic Wear Indicator

168-7720 Ultrasonic Wear Indicator III Group
SMCS: 0787
R NEHS0730-02
November 2005
TOOL
OPERATING
MANUAL
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Other Uses for the Indicator III . . . . . . . . . . . . . . . 3
Benefits of the Ultrasonic Wear Indicator III . . . . . 3
Features of the Indicator III . . . . . . . . . . . . . . . . . 3
General Measurement Benefits. . . . . . . . . . . . . . 4
Undercarriage Measurement Benefits . . . . . . . . 4
168-7720 Ultrasonic Wear Indicator III Group . . . 5
Storage of Conventional Tools . . . . . . . . . . . . . . 5
Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
168-7720 Ultrasonic Wear Indicator III Group
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
168-7722 Ultrasonic Probe Specifications . . . . . . 7
156-1077 Power Inverter Specifications . . . . . . . . 8
Connections to the 168-7721 Indicator III . . . . . . 8
168-7721 Indicator III Description . . . . . . . . . . . . 9
Abbreviations and Descriptions . . . . . . . . . . . . . 9
Description of Displays and Keys. . . . . . . . . . . . 9
Charging the Internal NiCad (rechargeable)
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing the Internal Rechargeable
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connecting to DC Power. . . . . . . . . . . . . . . . . . 14
Care and Cleaning of 168-7721 Indicator III . . . 15
Removing the 9U-7981 Couplant Residue . . . . 15
Cleaning the Case and Front Panel Key Pad. . 15
Care of Connectors. . . . . . . . . . . . . . . . . . . . . . 15
Operating Instructions for 168-7721
Indicator III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Turn the Indicator III ON . . . . . . . . . . . . . . . . . . 16
Calibrating the Indicator III and Probe . . . . . . . 16
Undercarriage Measurement Procedure . . . . . 18
Clearing the Memory. . . . . . . . . . . . . . . . . . . . . 18
Using the LOC(ation) Mode of Operation. . . . . 18
List of Undercarriage Storage LOC(ation)
Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Entering Information into the Indicator III . . . . . 20
Changing Displays with Words. . . . . . . . . . . . . 20
Measuring Track Sag . . . . . . . . . . . . . . . . . . . . 21
Taking Ultrasonic Measurements . . . . . . . . . . . 21
Saving Measured Values in Memory. . . . . . . . . 21
Tool Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Measurement Operating Tips . . . . . . . . . . . . . . 22
Undercarriage Measurement Techniques. . . . . . 23
Track Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Track Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Track Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Three-Piece Rims . . . . . . . . . . . . . . . . . . . . . . 24
Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Competitive Parts . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring the Thickness of Parts Other than
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transferring the Memory Values to or From a
Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Turnoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Beeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ultrasonic Velocity Adjustment . . . . . . . . . . . . . . 30
Checking the Ultrasonic Velocity . . . . . . . . . . . 30
Changing the Ultrasonic Velocity . . . . . . . . . . . 30
Battery Level Monitor . . . . . . . . . . . . . . . . . . . . . 31
Low Battery Indication . . . . . . . . . . . . . . . . . . . . 31
Return to Last Menu Screen . . . . . . . . . . . . . . . . 31
Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Viewing the Software Version Screen . . . . . . . . . 31
Checking the Operation of the Indicator III . . . . 32
Alternate Method. . . . . . . . . . . . . . . . . . . . . . . . 32
Adjusting the Displays Contrast . . . . . . . . . . . . . 32
Adjusting the Gain. . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 33
Undercarriage Measurement Display Map. . . . . 34
LOC(ation) Display Map . . . . . . . . . . . . . . . . . . . 35
9U-7981 Couplant Material Safety Data Sheet . . 37
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2
Introduction
Illustration 1. 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.
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
parts thickness by sending high frequency sound
waves through the material to be measured. When
the sound reaches the opposite side of the part, it
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 it.
When taking measurements, the 9U-7981 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.
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.
Benefits of the 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.
Features of the Indicator III
New design uses state-of-the-art surface mount
electronics for high reliability.
Easy 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 Indicator III Group includes
an updated probe with a longer, more durable
cable.
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.
3
General Measurement Benefits
Higher accuracy measurements. Digital display
of thickness is accurate to 0.1 mm (.01 in) for low
resolution mode, and 0.01 mm (.001 in) 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 accurately 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 edge, or scraper bowl thickness.
No writing. Stores readings in memory, then
transfers to a computer for printing.
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.
4
168-7720 Ultrasonic Wear
Indicator III Group
Illustration 2. 168-7721 Ultrasonic Wear Indicator III Group.
Refer to Chart A for item identification.
Storage Of Conventional Tools
Illustration 3. Storage For Conventional CTS Tools In
6V-7145 Carrying Case.
Refer to Chart B for item identification.
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.
5
Chart A.
168-7721 Ultrasonic Wear Indicator III
Item Part No. Description
1 168-7721 Ultrasonic Wear Indicator III
(Calibration Certificate not shown)
2 168-7722 Ultrasonic Probe
(Declaration of Conformity not shown)
3 9U-7981 Couplant
4 6V-7145 Carrying Case
5 4C-4772 Foam Insert
6 4C-3024 Battery Charger (110/220 Volts AC,
50/60 Hz)
7 Paper Towels (16 sheets from 9U-6000
Paper Towel Case)
NEEG2835 168-7720 Group Label (located in lid of
carrying case)
Four 1-9/16 inch protective caps for
RS232 connector
NEHS0730 Ultrasonic Wear Indicator III Group Tool
Operating Manual
Chart B.
Storage Locations
1 PEKP9400 Custom Track Service Handbook: Fits
under Indicator III
2 5P-3277 Tape Measure: 3 mm (10 ft) for pitch, sag,
and sprocket measurement
3 8H-8580 Scraper: For cleaning undercarriage
components
4 5P-8616 Sprocket Gauge: For D4, D5, and D6
Track-type Tractors
5 5P-8617 Sprocket Gauge: For D7, D8, and D9
Track-type Tractors
6 6V-9410 Depth Gauge: For measuring idlers
5P-3920 Steel Rule: 300 mm (12 in), store on top
of 9U-6000 Paper Towels
Optional Items
Illustration 4. Optional Items For 168-7721.
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.
Illustration 5. 168-7721 Indicator III With 168-7722 Probe
Installed In 9U-6175 Soft Protective Case.
6
Chart C.
Optional Items
1 4C-5488 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).
2 4C-5489 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).
3 4C-5897 Cable Assembly RS232 (Modem Cable):
For connecting the 168-7721 to a modem
which transfers data over telephone lines
to a personal computer.
4 1U-7445 NiCad (Nickel Cadmium) Rechargeable
Battery: (size AA) 1 per package.
5 1U-9533 Alkaline Battery: Non-rechargeable
battery (size AA) 96 per package.
6 156-1077 Power Inverter: For powering the 168-
7721 from 12VDC and includes battery
cables and a cigarette lighter.
7 9U-6175 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.
Additional Service Replacement Part (not
shown).
4C-5490 Couplant Holder: The service
replacement for the holder that stores the
9U-7981 Couplant container.
168-7720 Ultrasonic 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 IIIs back cover. See
Replacing the Internal Rechargeable Batteries
section for the procedure.
NOTICE
Wear Indicator III.
batteries.
Approximate Battery Life (with Indicator IIIs
backlight OFF and beeper ON).
NiCad Rechargeable . . . . . . . . . . . . . . . 19 Hours
Alkaline Non-rechargeable . . . . . . . . . . . 47 Hours
Approximate Battery Life (with Indicator IIIs
backlight and beeper ON).
NiCad Rechargeable . . . . . . . . . . . . . . . 14 Hours
Alkaline Non-rechargeable . . . . . . . . . . . 34 Hours
Indicator III shuts down . . . . . . . . . . . . . .5.12 volts
Power Line Operation:
4C-3024 Battery Charger . . . 110 or 220 Volts AC,
50/60 Hz.
Measurement Range (Steel) . . . 1.27 mm (.050 in)
to 254 mm (10.0 in)
Measuring Resolution:
Low Resolution (default) . . . . . 0.1 mm or (.01 in)
High Resolution . . . . . . . . . . 0.01 mm or (.001 in)
Measurement Accuracy:
Low Resolution (default) . . . . 0.1 mm or (0.01 in)
High Resolution . . . . . . . . 0.076 mm or (.003 in)
Operating Temperature . . . . . . . . . . -18C to 60C
(OF to 140F)
Storage Temperature:
Without Batteries Installed . . . . . . . . -40C to 60C
(-40F to 140F)
With Alkaline Batteries Installed . . . -40C to 50C
(less than 6 months) (-40F to 125F)
With NiCad Batteries Installed . . . . -20C to 45C
(less than 6 months) (-4F to 113F)
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 x 15.4 x 4.5 in)
168-7721 Indicator III . . . . . . . 190 x 168 x 40 mm
(7.5 x 6.6 x 1.6 in)
Weight:
168-7720 Group . . . . . . . . . . . . . . . . 3 kg (6.75 lb)
168-7721 Indicator III . . . . . . . . . . . 0.9 kg (2.0 lb)
168-7722 Probe . . . . . . . . . . . . . . 0.113 kg (.25 lb)
168-7722 Ultrasonic Probe
Specifications
Probe Type . . . . . . Dual Element 7.5 MHz special
application
Probe Size:
Measuring Surface Diameter . . . . . 11 mm (.43 in)
Length . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.65 in)
Diameter . . . . . . . . . . . . . . . . . . . . 19 mm (.748 in)
Allowable Surface Temperature . . -18C to 150C
(0F to 300F)
Cable Length . . . . . . . . . . . . . . . . 1524 mm (60 in)
Includes Certificate of Conformity
7
156-1077 Power 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 it is
connected to a 24 VDC battery)
Low Battery Indicator . . . . . . . . . . . . Audible alarm
sounds if input voltage drops to 10.6 VDC
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 VAC
Operating Temperature Range . . . . 10C to 26.7C
(50F to 80F)
Over Temperature Protection . . . . When the power
inverters internal heat sinks reach 65.5C (150F),
the inverter will automatically shut down. The
inverter may be restarted by first disconnecting
the inverter and allowing it to cool for 15 minutes
before reconnecting.
No Load Current Draw . . . . Less than 0.2 Ampere
Output Receptacle . . . . . . . . . . . . . . Dual 3-prong
Fuse . . . . . . . . . . . . . . . . . . . 35 Amp (spade type)
Weight . . . . . . . . . . . . . . . . . . . . . . 1.6 Kg (3.5 Ibs)
Dimensions . . . . . . . . . . . . . . . 155 x 127 x 58 mm
(6.1 x 5.0 x 2.3 in)
Maximum Continuous Power . . . . . . . . . 300 Watts
Surge Capability (Peak Power) . . . . . . . . 600 Watts
Overload Protection . . . . . . . Inverter automatically
shuts down if continuous power
is greater than 300 Watts
Connections to the 168-7721
Indicator III
Illustration 6. Connectors For 168-7721.
Refer to Chart C for item identification.
8
Chart D.
Connectors For 168-7721 Indicator III
1 9U-7981 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.
2 4C-5490 Holder
Used to hold the 9U-7981 Couplant
Dispenser
3 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 Calibrating
the Ultrasonic Wear Indicator III in this
manual.
4 RS232 Connector (shown without 1 9/16
protective cap installed)
Used to connect
4C-5488 Cable As. RS232 (PC AT) or
4C-5489 Cable As. RS232 (PC XT) or
4C-5897 Cable As. 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 Optional Items in this
manual, for each cables specific function
and software program requirements.
5 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-4032 can be
plugged into the 156-1077 Power Inverter
to provide 12 VDC power for powering the
indicator.
6 Probe Connector
Used to install the 168-7722 or 4C-5485
Ultrasonic Probe.
7 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.
168-7721 Indicator III
Description
Illustration 7. 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 (.25 in):
Describes the metal calibration disks thickness
measured in millimeters and inches during
probe calibration (metal calibration disk is
located on top panel).
3. RS232:
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 Optional Items
(in this manual) for each cables specific
function, software program 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, it 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 Illustration 7, 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 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.
9
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 Ultrasonic 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
or (.25 in) while in the Low Resolution mode,
press PROBE CAL while holding the probe on
the disk and it should read correctly.
If the MEASURED VALUE display is not in the
range of 6.25 to 6.32 mm or (.246 to .249 in)
while in the High Resolution mode, press
PROBE CAL while holding the probe on the
disk and it should read correctly.
Refer to Calibrating the Ultrasonic Wear
Indicator III and Checking the Ultrasonic
Velocity 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
Settings Menu in this manual.
15. CLR/CLR MACH:
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:
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.
10
18. UP ARROW / BACKLIGHT:
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 displays
backlight. Perform the same keystrokes to turn
the backlight OFF.
NOTE: When Ultrasonic Wear Indicator III is in
Manual Turnoff 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.
11
Charging the Internal NiCad
(rechargeable) Batteries
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.
Illustration 8. Rear View Of 4C-3024 Battery Charger.
Procedure
1. Move switch (1) on the rear of 4C-3024 Battery
Charger (2) to the correct AC line voltage, either
120 Volts or 230 Volts, depending on use.
2. Connect charger connector (3) into the
CHARGE connector located on the top of the
Indicator III.
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).
These can be replaced with new 1U-7445 Batteries
when they no longer give sufficient operating time,
or they can be replaced with 1U-9533 Alkaline
(non-rechargeable) Batteries.
NOTE: The internal batteries can be removed
indefinitely and the internal memory values will not
be affected.
NOTICE
Wear Indicator III.
batteries.
Illustration 9. Back View Of 168-7721 Ultrasonic Wear
Indicator III.
1. Remove two screws (1) from battery cover (2).
2. Remove battery cover (2).
12
Illustration 10. Indicator III With Battery Cover Removed.
3. Remove all batteries (3) and replace with new
batteries.
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
Illustration 11 and 12).
Illustration 11. Indicator III With Batteries Removed.
(4) + or positive terminal.
Illustration 12. Enlarged View Of Battery Compartment.
(4) + or positive terminal.
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 a (+) sign
by it inside of the battery compartment (5).
Compress the negative battery contact as much as
possible (see Illustration 13) and then install the
plus terminal (+) of the battery into the battery
compartment.
Illustration 13. Installing Battery Cover.
(5) Battery () negative terminal. (6) Battery (+) positive
terminal.
5. Install battery cover (2) and replace two
screws (1).
13
Connecting to DC Power
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 Illustration
8 and 14.
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's negative
terminal. Connect the power cable clip with the
red colored handle to the battery's positive
terminal.
NOTICE
The 156-1077 Power Inverter requires a 12 VDC
input. Make sure not to exceed this specification
or the power inverter's 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 Ampere
fuse. Refer to item 5, illustration 9.
4. The 168-7721 Indicator can also be powered by
a vehicle's 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 Illustration 14.
Illustration 14. 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 cable's plug supplied with the
emission analyzer. (8) ON/OFF switch.
14
Care and Cleaning of 168-7721
Indicator III
The 168-7721 Ultrasonic Wear Indicator III is a
durable hand-held instrument. However, since it
will be used outdoors in a wide range of conditions,
care must be taken to protect it and 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
it to dry completely in a warm, dry area.
Keep the Indicator III stored in the carrying case
when not in use.
Removing the 9U-7981 Couplant
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.
However, care must be taken so no water enters
the Indicator III case.
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
on it. Keep this cap in place at all times when this
connector is not being used. Extra plastic caps are
included with the group.
15
Operating Instructions for
168-7721 Indicator III
Plug the connector on the end of the 168-7722 or
4C-5485 Ultrasonic Probe Cable into the probe
connector on the top of the Indicator III.
Turn the Indicator III ON
1. Press and release the ON/OFF key.
Copyright Display.
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.
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.
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.
Calibrating the Indicator III and 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 Ultrasonic Velocity Adjustment in
this manual.
Illustration 15. Applying Couplant To Ultrasonic Probe.
15 MACH D8N
9TC1840
1 MACH (CLEAR)
CATERPILLAR INC.
COPR. 1989-1999
16
Illustration 16. Ultrasonic Wear Indicator III And Probe
Being Calibrated.
A metal calibration disk, Illustration 16, 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 Illustration 15.
2. Press the probe against the metal calibration
disk on the top of the Indicator III.
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.
Probe On Calibration Disk NOT In Calibration.
NOTE: The thickness value and its units
(i.e. 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 or (.25 in)
when in the Low Resolution Mode. If it is not
correct, as shown in step 3, follow the
instructions in Step 6.
Probe Removed From Calibration Disk.
5. If the calibration is correct, as shown in step 4,
proceed to the Undercarriage Measurement
Procedure section.
6. To calibrate the Indicator III and probe, press
the PROBE CAL key. The display should now
show (PROBE).
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.
Calibration Complete.
8. The MEASURED VALUE, shown in step 7,
should now be correct. If not, repeat this
procedure until it is 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 Ultrasonic Velocity
Adjustment in this manual.
15 MACH (CLEAR)
0.24 IN
(PROBE)
15 MACH (CLEAR)
0.25
15 MACH (CLEAR)
0.24 IN
17
Procedure
NOTE: When using this procedure, refer to the
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 Calibrating
the Ultrasonic Wear Indicator III section.
2. After calibration, use the up or down arrow keys
to select a (CLEAR) machine or to locate the
specific machine you are measuring.
Clearing the Memory
1. If a (CLEAR) machine cannot be located, any
one or all machine(s) can be cleared by first
pressing and releasing the red SHIFT key and
then pressing CLR MACH key.
2. Press the VALUE key to clear one machine
(Machine 2 in this example).
Display while one machine is being cleared.
The message shown above will appear on the
display for a short period of time.
3. The (CLEAR) message indicates the memory
has been cleared and is ready for new data.
NOTE: When a MACH memory is cleared, the data
that was in the memory for that MACH number will
be lost and cannot be retrieved.
MACH Display After Clearing Machine Memory.
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.
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.
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 of
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 the
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 Undercarriage
Measurement Display Map in this manual for
additional information on how to change between
the various displays.
CLR ALL MACH
2 MACH (CLEAR)
CLR MACH 2
CLR MACH 2
CLR ALL MACH
18
List of Undercarriage Storage
LOC(ation) Displays
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.
19
Loc. Display Notes
1 MODEL The machine model number
2 SERIAL NUMBER The machine serial number
3 DATE MM/DD/YYYY The date by month, day, year
DATE DD/MM/YYYY The date by day, month, year
4 HOURS The service hour meter reading
on the machine
5 HRS. / WEEK The number of hours the
machine has worked per week
6 MILES The reading on the machines
KM odometer in miles or kilometers
7 MILES/WEEK The distance the machine has
KM/WEEK traveled per week
8 JOB SITE The location of the machine
9 IMPACK COND The underfoot conditions -
Impact, use SET DIGIT:
MODERATE, HIGH, LOW
10 ABRASIVE COND The underfoot conditions -
Abrasive, use SET DIGIT:
MODERATE, HIGH, LOW
11 MOISTURE COND The underfoot conditions-
Moisture, use SET DIGIT:
MODERATE, HIGH. LOW
11 PACKING COND The underfoot Conditions
Packing, use SET DIGIT:
MODERATE, HIGH. LOW
13 BUSHING ALLOW Bushing allowable wear, use SET
DIGIT: GREATER, LESSER
14 L TRACK SAG Left track sag - use SET DIGIT
15 L DRY JOINTS Left dry joints - use SET DIGIT
16 L LINK Left link measurement
17 L BUSH INT Left bushing internal wear - use
SET DIGIT
18 L BUSHING EXT Left bushing external wear
19 BUSHING TOOL Measuring tool used on bushings
(EXT). SET DIGIT: ULTRASONIC,
CALIPER, DEPTH GAUGE
20 L SHOE Left shoe measurement
21 SHOE TOOL Measurement tool used on
shoes, SET DIGIT:
ULTRASONIC, DEPTH GAUGE
22 F IDLER DEPTH Front idler depth gauge
measurement - use SET DIGIT
23 F IDLER SONIC Front idler ultrasonic
24 R IDLER DEPTH Rear idler depth gauge meas.
25 R IDLER SONIC Rear idler ultrasonic measurement
26 L CAR. ROLL 1 Left carrier roller number 1
29 CAR ROLL TOOL Measuring tool used on carrier
rollers. SET DIGIT:
ULTRASONIC, CALIPER
30 L ROLLER 1 Left track roller number 1
Loc. Display Notes
40 ROLLER TOOL Measuring tool used on track
rollers. SET DIGIT:
ULTRASONIC, CALIPER, DEPTH
GAUGE
41 L SPROCKET Left sprocket - use SET DIGIT
42 R TRACK SAG Right track sag - use SET DIGIT
43 R DRY JOINTS Right dry joints - use SET DIGIT
44 A LINK Right link measurement
45 A BUSHING INT Right bushing internal wear -
use SET DIGIT
46 A BUSHING EXT Right bushing external wear
47 R SHOE Right shoe measurement
48 F IDLER DEPTH Front idler depth gauge
49 F IDLER SONIC Front idler ultrasonic
measurement
50 R IDLER DEPTH Rear idler depth gauge
51 R IDLER SONIC Rear idler ultrasonic
measurement
52 A CAR. ROLL 1 Right carrier roller number 1
53 R CAR. ROLL 2 Right carrier roller number 2
54 A CAR. ROLL 3 Right carrier roller number 3
55 A ROLLER 1 Right track roller number 1
56 R ROLLER 2 Right track roller number 2
60 A ROLLER 6 Right track roller number 6
65 R SPROCKET Right sprocket - use SET DIGIT
66 NOTES LINE 1 16 characters - use SET DIGIT
70 SPARE #1 For extra measurement
71 SPARE #2 For extra measurement
MODEL display with empty MODEL number.
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) to LOC(ation) mode
of operation.
Entering Information into the
Indicator III
If the memory contains a MODEL number, it will
always be shown on the display. If it does not
contain a MODEL number, dashed lines will show
where the 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.
To enter the serial (product identification) number
into the SERIAL NUMBER display, follow the same
procedure as used in the Using LOC(ation) Mode
of Operation section.
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
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.
Example of IMPACT with alternate word
MODERATE.
Example of IMPACT with alternate word HIGH.
Example of IMPACT with alternate word LOW.
2 IMPACT COND
2 LOW
2 IMPACT COND
2 HIGH
2 IMPACT COND
2 MODERATE
2 MODEL
D8N
2 MODEL
- - - - - - - - -
20
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 it on the display and press the up arrow key
to move on to the next location. The selected word
will always reappear on 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. It must be taken
according to the instructions in the CTS handbook
with a tape measure and manually entered into the
Indicator IIIs 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 topic Entering Information into the
Ultrasonic Wear Indicator III section.
3. When the proper number has been entered,
press the SAVE key to continue with the next
reading.
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 Undercarriage Measurement
Techniques section, 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 it 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
(i.e. 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.
NOTE: Measurements can only be taken in the
MACH(ine) Display Mode or in a LOC(ation)
Display Modes screen that accepts ultrasonic
measurements.
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 just 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.
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:
Example of BUSHING TOOL with type of tool used:
ULTRASONIC
CALIPER
DEPTH GAUGE
1 BUSHING TOOL
3 DEPTH GAUGE
1 BUSHING TOOL
2 CALIPER
1 BUSHING TOOL
1 ULTRASONIC
21
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.
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 easily 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 topic entitled List of Undercarriage Storage
Location Displays section.
After taking the 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 a 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
the probe off quickly to prevent the
measurement from increasing slightly as the
probe is removed.
22
Techniques
Track Links
Illustration 17. Measuring Track Links.
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 Shoes
Illustration 18. Probe Located On The Bottom Of The
Plate.
1. Measure the distance from the bottom of the
plate to tip of the grouser.
Illustration 19. 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.
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.
Track Bushing
Illustration 20.
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.
23
Idler
Illustration 21.
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
Illustration 22. Measure The Thickness Of Press-On Rim.
Illustration 23.
Illustration 24. 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.
24
Track Roller
Illustration 25.
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 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.
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 always 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 are to check the
wall thickness of a:
Bulldozer blade
Bucket base edge
Scraper bowl
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 Ultrasonic Velocity Adjustment section in this
manual for complete information on measuring
materials other than steel.
1. Install 168-7722 or 4C-5485 Probe, and
calibrate the Indicator III and probe. Refer to
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 Ultrasonic
Velocity Adjustment in this manual.
25
Transferring the Memory
Values to or From a Computer
The information contained (saved) in the
Indicator IIIs 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 before the
transfer.
2. The user can select where the machines 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 machine(s) beginning with the
MACH(ine) No. shown on the Indicator IIIs
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.
NOTE: When transferring machine data from a PC
to the Indicator III, the Indicator III does not wrap
around the 64 MACH(ine) locations, i.e. the data
from three machines is transferred from the PC,
MACH(ine) memory in the Indicator III is not empty,
and the Indicator III's 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 in
MACH(ine) 64.
Settings Menu
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
illustration 26. 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. Illustration 27 shows the different
settings that can be selected with each function in
the Settings Menu.
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 IN].
2. High Resolution mode is 0.00 MM [0.000 IN].
Turnoff
This function allows for longer battery life by
automatically turning the Indicator III OFF if it has
not been used for five 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.
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.
26
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.
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 by 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 setting).
2. FRENCH.
3. GERMAN.
4. PORTUGUESE.
5. SPANISH.
Distance
Allows the units for distance to be changed:
1. MILES (default setting).
2. KM - Kilometers.
Date
This function allows date configuration to be
selected:
1. MM/DD/YYYY - Month, Day, and Year (default
setting).
2. DD/MM/YYYY - Day, Month, and Year.
27
28
RESOLUTION
0.0MM [0.00IN]
TURNOFF
AUTO
VELOCITY
OFF
LANGUAGE
ENGLISH
BEEPER
ON
BLUE SHIFT + SET KEYS
(ENTER SETTINGS MENU)
SERIAL
9600
DATE
MM/DD/YYYY
DISTANCE
MILES
BLUE SHIFT + SET KEYS
(EXIT SETTINGS MENU)
ARROW
KEYS
ARROW
KEYS
ARROW
KEYS
ARROW
KEYS
ARROW
KEYS
ARROW
KEYS
ARROW
KEYS
0730-35
Illustration 26. Settings Menu Operation (default states shown).
Illustration 27. Settings Menu Operation.
29
DISTANCE
MILES
DISTANCE
KM
DATE
MM/DD/YYYY
DATE
DD/MM/YYYY
DEFAULT DEFAULT
VALUE KEY VALUE KEY
TURNOFF
AUTO
TURNOFF
MANUAL
DEFAULT DEFAULT
VALUE KEY VALUE KEY
RESOLUTION
0.0MM [0.00IN]
RESOLUTION
0.00MM [0.000IN]
DEFAULT DEFAULT
VALUE KEY VALUE KEY
VELOCITY
OFF
VELOCITY
ON
BEEPER
ON
BEEPER
OFF
DEFAULT
VALUE KEY
SERIAL
9600
SERIAL
1200
VALUE KEY
SERIAL
19200
VALUE KEY
DEFAULT
VALUE KEY VALUE KEY
LANGUAGE
ENGLISH
VALUE KEY VALUE KEY
LANGUAGE
LANGUAGE
FRENCH
LANGUAGE
SPANISH
LANGUAGE
GERMAN
LANGUAGE
PORTUGUESE
VALUE KEY
VALUE KEY
0730-36
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/SEC) or inches per
microsecond (IN/SEC) that sound travels through
different materials.
Refer to Chart E for a list of various materials,
ultrasonic velocities, and probe calibration values.
1
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 Settings
Menu section).
2. With the Indicator III ON, make sure display is in
the MACH(ine) display mode, then press the
MM/INCH key.
Example of Screen Display with VEL in MM/SEC.
Example of Screen Display with VEL in IN/SEC.
The velocity setting of the Indicator III will appear
on the bottom line of the display, as shown above.
Either MM or IN will be displayed, depending on
which was being used earlier.
3. If the Indicator III is being used to measure
Undercarriage Steel, be sure it reads
5.87 MM/SEC or (.231 IN/SEC), 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 Changing the
Ultrasonic Velocity section.
Changing the Ultrasonic Velocity
1. Locate the velocity number for the material to be
measured in Chart E. The numbers given in
Chart E are approximate, and slightly different
numbers may have 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 chart 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 or (.25 in).
5. Measure a known thickness of the new material
with the Indicator III to be sure the readings are
accurate.
6. If the readings are not exact, change the
velocity setting number right-hand digit by one
and recalibrate.
7. Measure the material again and continue this
process until the Indicator III reads correctly.
1 MACH (CLEAR)
VEL=.231 IN/USEC
1 MACH (CLEAR)
VEL=5.87 MM/USEC
30
Chart E.
Velocity
MM/EC Probe CAL
1
Material (IN/SEC) Measured Value
Aluminum 6.09 (.240) 6.3 mm (.25 in)
Cast Iron 4.57 (.180) 4.8 mm (.19 in)
Copper 4.57 (.180) 4.8 mm (.19 in)
Glass 5.33 (.210) 5.6 mm (.22 in)
Mild Steel 5.84 (.230) 6.3 mm (.25 in)
Plastic (Plexiglass) 2.67 (.105) 2.8 mm (.11 in)
Stainless Steel 5.84 (.230) 6.3 mm (.25 in)
Tin 3.30 (.130) 3.6 mm (.14 in)
Undercarriage Steel 5.87 (.231) 6.3 mm (.25 in)
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 Volts. A value of 0%
will be displayed anytime the battery voltage falls to
5.4 Volts or less. The Battery Level Monitor screen
will appear as follows:
NOTE: If using NiCad rechargeable batteries, they
must be fully charged before each use for the
Battery Level Monitor to work correctly. Refer to
Batteries section.
Low Battery Indication
The LCD display will flash for at least 30 seconds
when the battery voltage reaches 6.14 volts, which
is when a minimum of 2 hours of battery life is left.
It will then stop flashing for a period of about thirty
minutes and return to at least a 30 second flashing
period. When the Indicator III has reached a
minimum of one 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 volts.
NOTE: If using NiCad rechargeable batteries, they
must be fully charged before each use for the Low
Battery Indication to work correctly. Refer to
Batteries section.
NOTE: When the probe is coupled and the
Indicator IIIs 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.
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
(i.e. by pulling batteries out 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 their 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 three seconds. The
Indicator III will turn ON and will display "FACTORY
RESET" while the factory reset is being performed.
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.
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 period of time will not affect the
memory.
SOFTWARE VERSION
3.1
BATTERY POWER
70 PERCENT
31
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 or 4C-5485 Probe. The only
components required for the test are the 168-7721
Ultrasonic Wear Indicator III, 168-7722 or 4C-5485
Probe, and 9U-7981 Couplant.
Perform all the procedures, as shown in Operating
Instructions for the 168-7721 Ultrasonic Wear
Indicator 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 they operate
correctly.
If the Indicator III does not operate properly
during this test, refer to the Troubleshooting
section 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 very 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 Troubleshooting section
in this manual for the procedures to adjust the
gain.
5. This completes the test of the Indicator III.
Adjusting the Display's
Contrast
The display's contrast may be adjusted to the
user's preference. The contrast has been set at the
factory. If it is determined it needs to be changed,
use the following procedures:
1. Remove six screws from the back cover and
remove the cover.
2. Locate contrast adjustment (Illustration 28) 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's contrast.
Marking this position will allow you to return it to
its original setting, if desired.
4. To adjust the display's contrast, use a small flat
head screwdriver to turn the contrast while
viewing the display's screen. Continue to adjust
until the information on the screen is clear to the
user's preference. Once the setting is obtained,
replace the rear cover.
Illustration 28. Cover removed to access the gain and
display's contrast adjustments.
(1) RP1 Gain adjustment. (2) RP2 Display's contrast
adjustment.
32
Adjusting the Gain
If the gain is out of adjustment. it will result in
inaccurate or hard to get readings, or no echo. If it
is determined 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 absolutely necessary.
1. Remove six screws from the back cover and
remove the cover.
2. Locate gain adjustment (Illustration 28) on the
top printed circuit board.
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 it to its original setting if you
have trouble with the operation of the Indicator
III during this procedure.
4. Make sure 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.
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 them 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 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 Service section in this
manual.
If the display comes on but the Indicator III will not
take measurements, the problem may be in the
probe.
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.
33
34
SOFTWARE VERSION
3.1
CATERPILLAR INC.
COPR. 1989-1999
FACTORY RESET
CLR
ON
OFF
1 MACH (CLEAR)
2 MACH (CLEAR)
3 MACH (CLEAR)
4 MACH (CLEAR)
5 MACH (CLEAR)
64 MACH (CLEAR)
63 MACH (CLEAR)
1 SERIAL NUMBER

1 MM/DD/YYYY
DATE 01 / 01 / 1999
1 HOURS

1 HRS. / WEEK

1 JOB SITE

1 MODEL

1 IMPACT COND
2 MODERATE
1 ABRASIVE COND
2 MODERATE
1 MOISTURE COND
2 MODERATE
1 MODEL

1 MODEL
D
1 MODEL
D
1 MODEL
D9
1 MODEL
D9
1 IMPACT COND
3 HIGH
1 IMPACT COND
1 LOW
ON
OFF
LOC
MACH
ON
OFF
HOLD PUSH PUSH
PUSH AND HOLD BOTH KEYS
AT SAME TIME FOR 3 SECONDS
KEYS
MACHine
DISPLAYS
ARROW
KEYS
LOC/MACH
KEY
LOCation
DISPLAYS
TYPICAL
DISPLAYS
VALUE
KEY
ARROW
KEYS
RED
SHIFT "D" KEY
"9" KEY
SAVE
KEY
VALUE
KEY
ARROW
KEYS
TO PACKING COND
DISPLAY
CLR
MACH
1 MILES

1 MILES / WEEK

0730-30
Undercarriage Measurement Display Map
NOTE: Settings menu in default states.
35
VALUE
KEY
ARROW
KEYS
1 PACKING COND
2 MODERATE
1 R IDLER DEPTH
0.00 0.00IN
1 BUSHING TOOL
2 CALIPER
1 BUSHING TOOL
3 DEPTH GAUGE
VALUE KEY
ARROW KEYS ARROW KEYS
1 F IDLER DEPTH
0.00 0.00IN
1 F IDLER SONIC
0.00 0.00IN
1 R IDLER SONIC
0.00 0.00IN
1 BUSHING ALLOW
2 GREATER
1 L TRACK SAG
0.00 0.00IN
1 L DRY JOINTS

1 L LINK
0.00 0.00IN
1 L BUSHING INT
0.00 0.00IN
1 L BUSHING EXT
0.00 0.00IN
1 BUSHING TOOL
1 ULTRASONIC
1 L SHOE
0.00 0.00IN
1 SHOE TOOL
1 ULTRASONIC
1 L CAR. ROLL 1
0.00 0.00IN
1 L CAR. ROLL 2
0.00 0.00IN
1 L CAR. ROLL 3
0.00 0.00IN
1 CAR ROLL TOOL
1 ULTRASONIC
1 L ROLLER 1
0.00 0.00IN
1 L ROLLER 2
0.00 0.00IN
1 L ROLLER 3
0.00 0.00IN
1 L ROLLER 4
0.00 0.00IN
1 L ROLLER 5
0.00 0.00IN
1 L ROLLER 6
0.00 0.00IN
FROM MOISTURE COND
DISPLAY
TO L ROLLER 7
DISPLAY
0730-31
LOCation Display Map
NOTE: Settings menu in default states and units are inches.
36
ARROW KEYS ARROW KEYS
BACK TO START
MODEL DISPLAY
ARROW KEYS
FROM L ROLLER 6
DISPLAY
END
1 R ROLLER 6
0.00 0.00IN
1 F IDLER DEPTH
0.00 0.00IN
1 F IDLER SONIC
0.00 0.00IN
1 ROLLER TOOL
1 ULTRASONIC
1 R ROLLER 7
0.00 0.00IN
1 R ROLLER 8
0.00 0.00IN
1 R ROLLER 9
0.00 0.00IN
1 R ROLLER 10
0.00 0.00IN
1 L ROLLER 7
0.00 0.00IN
1 L ROLLER 8
0.00 0.00IN
1 L ROLLER 9
0.00 0.00IN
1 L ROLLER 10
0.00 0.00IN
1 L SPROCKET

1 R TRACK SAG
0.00 0.00IN
1 R DRY JOINTS
21
1 R LINK
0.00 0.00IN
1 R BUSHING INT
0.00 0.00IN
1 R BUSHING EXT
0.00 0.00IN
1 R SHOE
0.00 0.00IN
1 R IDLER DEPTH
0.00 0.00IN
1 R IDLER SONIC
0.00 0.00IN
1 R ROLLER 5
0.00 0.00IN
1 R ROLLER 4
0.00 0.00IN
1 R ROLLER 3
0.00 0.00IN
1 R ROLLER 2
0.00 0.00IN
1 R ROLLER 1
0.00 0.00IN
1 R CAR. ROLL 1
0.00 0.00IN
1 R CAR. ROLL 2
0.00 0.00IN
1 R CAR. ROLL 3
0.00 0.00IN
1 R SPROCKET

1 NOTES LINE 1

1 NOTES LINE 2

1 NOTES LINE 3

1 NOTES LINE 4

1 SPARE #1
0.00 0.00IN
1 SPARE #1
0.00 0.00IN
0730-32
LOCation Display Map (contd)
9U-7981 Couplant 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
Product Name . . . . . 9U-7981 Ultrasonic Couplant
Generic Name . . . . . . . . . . . . Ultrasound Couplant
NFPA Hazardous Materials Identification System (est)
Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Flammability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Reactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Section 2 Hazardous Ingredients
None
Section 3 Physical Data (nominal)
Boiling Point . . . . . . . . . . . . >220F pH: 7.35 to 7.9
Freezing Point . . <20F Acoustic Imp.: 1.726 x 10
6
Vapor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Vapor Density . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Evaporation Rate . . . . . . . . . . . . . . . . . . . . . . . N/A
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . >1.02
Solubility in Water . . . . . . . . . . . . . . . . . . Complete
Appearance and Odor . . Water white, opaque gel;
bland odor
Section 4 Fire and Explosion Hazard
Data
Flash Point . . . . . . . . . . . . . . . . . . . . . . . . . . . none
Upper Exposure Limit . . . . . . . . . . . . . . . . . . . none
Lower Exposure Limit . . . . . . . . . . . . . . . . . . . none
Special Fire Fighting Procedures . . . . . . . . . . . N/A
Extinguishing Media . . . . . . . . . . . . . . . . . . . . . N/A
Unusual Fire and Explosion Hazards . . . . . . . none
Section 5 Reactivity Data
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stable
Conditions to Avoid . . . . . . . . . . . . . . . . . . . . . none
Incompatibility (Materials to Avoid) . . . none known
Hazardous Polymerization . . . . . . . . . will not occur
Hazardous Decomposition or Byproducts . . . none
known
Section 6 Health Hazard and First Aid
Data
Routes of Entry
1
:
Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . not likely
Ingestion . . . . . . . . . . . . . . . . . . . . . . not normally
Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . not normally
Inhalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no
Effects of Overexposure:
Acute . . . . . . . may cause temporary eye irritation
Chronic . . . . . . . . . . . . . . . . . . . . . none expected
First Aid Procedures:
Skin . . . . . . . . . . . . Remove with water if desired.
Eyes . . . . . . . . . . Flush with water for 15 minutes.
Ingestion . . . . . . . . . . For large quantities, induce
vomiting and call a physician.
Inhalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Section 7 Storage and Handling
Information
Precaution to be taken in handling and storage:
Store between 20F and 120F. Spills are slippery
and should be cleaned up immediately.
Steps to be taken in case material is released or
spilled:
Pick up excess for disposal. Clean with water.
Waste disposal method:
Dispose of in accordance with federal, state, and
local regulations.
Section 8 Control Measures
Respiratory Protection . . . . . . . . . . . . . not required
Ventilation . . . . . . . . . . . . . . . . . . . . . . not required
Protective Gloves . . On individuals demonstrating
sensitivity to 9U-7981 Couplant.
Eye Protection . . . . . . . . . . . . . . . . . As required by
working conditions
Other Protective Equipment . . . . . . . . not required
1
9U-7981 Ultrasonic Couplant contains only food
grade and cosmetic grade ingredients.
37
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
Troubleshooting section 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's user
with a warranty of one 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.
For any product support questions with your
instrument, contact Dealer Service Tools at:
501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com
If the instrument, or any part of it needs repair, then
contact and send it to:
ATS (Advanced Technology Services)
8201 North University Avenue
Peoria, Illinois USA 61615
Phone: (800) 328-7287 (Inside USA)
(309) 693-4000
Fax: (309) 693-4170
E-mail repair@advancedtech.com"
38
NOTES
39
For information on service tools or shop supplies,
contact Dealer Service Tools on:
Dealer Service Tools
501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com
2005 Caterpillar
All Rights Reserved
NEHS0730-02
Printed in U.S.A.

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