168-7720 Ultrasonic Wear Indicator III Group

SMCS: 0787

R NEHS0730-02November 2005

TOOLOPERATINGMANUAL

Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Other Uses for the Indicator III . . . . . . . . . . . . . . . 3

Benefits of the Ultrasonic Wear Indicator III . . . . . 3Features of the Indicator III . . . . . . . . . . . . . . . . . 3General Measurement Benefits. . . . . . . . . . . . . . 4Undercarriage Measurement Benefits . . . . . . . . 4

168-7720 Ultrasonic Wear Indicator III Group . . . 5Storage of Conventional Tools . . . . . . . . . . . . . . 5

Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

168-7720 Ultrasonic Wear Indicator III GroupSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7168-7722 Ultrasonic Probe Specifications . . . . . . 7

156-1077 Power Inverter Specifications . . . . . . . . 8

Connections to the 168-7721 Indicator III . . . . . . 8

168-7721 Indicator III Description . . . . . . . . . . . . 9Abbreviations and Descriptions . . . . . . . . . . . . . 9Description of Displays and Keys. . . . . . . . . . . . 9

Charging the Internal NiCad (rechargeable)Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Replacing the Internal Rechargeable Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Connecting to DC Power. . . . . . . . . . . . . . . . . . 14

Care and Cleaning of 168-7721 Indicator III . . . 15Removing the 9U-7981 Couplant Residue . . . . 15Cleaning the Case and Front Panel Key Pad . . 15Care of Connectors . . . . . . . . . . . . . . . . . . . . . . 15

Operating Instructions for 168-7721 Indicator III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Turn the Indicator III ON . . . . . . . . . . . . . . . . . . 16Calibrating the Indicator III and Probe . . . . . . . 16Undercarriage Measurement Procedure . . . . . 18Clearing the Memory. . . . . . . . . . . . . . . . . . . . . 18Using the LOC(ation) Mode of Operation. . . . . 18List of Undercarriage Storage LOC(ation) Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Entering Information into the Indicator III . . . . . 20Changing Displays with Words . . . . . . . . . . . . . 20Measuring Track Sag . . . . . . . . . . . . . . . . . . . . 21Taking Ultrasonic Measurements . . . . . . . . . . . 21Saving Measured Values in Memory. . . . . . . . . 21Tool Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Measurement Operating Tips . . . . . . . . . . . . . . 22

Undercarriage Measurement Techniques. . . . . . 23Track Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Track Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Track Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 23Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Three-Piece Rims . . . . . . . . . . . . . . . . . . . . . . 24

Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Competitive Parts . . . . . . . . . . . . . . . . . . . . . . . 25Measuring the Thickness of Parts Other thanUndercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Transferring the Memory Values to or From aComputer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Turnoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Beeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Ultrasonic Velocity Adjustment . . . . . . . . . . . . . . 30Checking the Ultrasonic Velocity . . . . . . . . . . . 30Changing 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 . . . . 32Alternate Method. . . . . . . . . . . . . . . . . . . . . . . . 32

Adjusting the Display’s Contrast . . . . . . . . . . . . . 32Adjusting 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 Groupprovides a new, fast, and accurate method ofmeasuring track-type machine undercarriage wear.

By placing a probe on the part to be measured, theUltrasonic Wear Indicator III will show the partthickness on the two-line alpha numeric display.The indicator also guides the operator by indicatingthe undercarriage components to be measured.The thickness values can be stored in internalmemory for recall later. This stored information maybe transferred to a computer for printing.

The Custom Track Service (CTS) personalcomputer program is available and when used withthe Ultrasonic Wear Indicator III, will provideundercarriage wear reports directly from the storedmeasurements. This new CTS tool provides aprofessional alternative for the mechanical CTS toolkit.

The Ultrasonic Wear Indicator III measures thepart’s thickness by sending high frequency soundwaves through the material to be measured. Whenthe sound reaches the opposite side of the part, itis reflected back and received by the probe. Thetime required for the sound to travel through thepart and be received determines the thickness ofthe part. The microprocessor in the Indicator IIIconverts the time into a thickness value anddisplays it.

When taking measurements, the 9U-7981 Couplantmust be applied to the sensing end of the probebefore measuring. This allows the sound to betransferred into the part being measured. Forconvenience, the couplant container attaches tothe side of the Indicator III.

Other Uses for the Indicator IIIQuick and accurate, nondestructive thicknessmeasuring of track beds, truck bed liners,bulldozer blades, bucket base edges, bucketcutting edges, scraper bowls, and even materialslike aluminum, plastic, copper, and glass.

Benefits of the UltrasonicWear Indicator IIIFor many years, CTS inspectors have used themechanical CTS kit to measure undercarriage wear.While this method worked, the new Ultrasonic WearIndicator III has many benefits over the previousmeasurement method. These features and benefitsare 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 batterycover screws on the back of the Indicator III.

• Backlit Liquid Crystal Display can be turned ON or OFF.

• Power Level Monitor shows estimated batterypower remaining in percent.

• Mono earphone connector accepts earphone tohear beeper when working in a noisyenvironment.

• Built-in multiple language capability with English,Portuguese, French, Spanish, and Germanlanguages. (Program modules no longer neededto switch languages.)

• 168-7720 Ultrasonic Indicator III Group includesan updated probe with a longer, more durablecable.

• Used with Custom Track Service (CTS)inspections, which can be downloaded directlyto a computer for viewing or printing.

• Uses five Alkaline or Nicad AA batteries (no battery pack).

• Automatically recalls and shows last machine orlocation display screen used when turned ON.

• When transferring machine data from a PC to theIndicator III, the user can select where the datawill be stored.

3

General Measurement Benefits• Higher accuracy measurements. Digital display

of thickness is accurate to 0.1 mm (.01 in) for lowresolution mode, and 0.01 mm (.001 in) for highresolution mode.

• Time savings in measuring undercarriage due toreduced cleaning and measurement storage.

• Easy to use. Thickness reading will alwaysappear on the display when the probe is used,regardless of mode of operation.

• Calibrated for undercarriage steel, but velocitycan be adjusted to accurately measure othermaterials such as aluminum, plastic, and glass.

• Reads thickness of parts where opposite side isnot accessible, such as a bulldozer blade,bucket base edge, or scraper bowl thickness.

• No writing. Stores readings in memory, thentransfers to a computer for printing.

Undercarriage MeasurementBenefits• Less time cleaning parts. Only a small surface

on the wear area must be cleaned. Onbushings, the back side, between the bushingand shoe, does not require cleaning.

• Measures track idler center flange thickness.

• Eliminates errors caused by dirt packed aroundparts.

• Accurately measures bushing wear after turning.

• Stores information from 64 machines.

• All CTS inspectors measure with the sameaccuracy because the CTS computer programdirectly calculates percent wear and projectedlife.

• Prompts CTS inspector on next reading location.

4

168-7720 Ultrasonic WearIndicator 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 In6V-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 cannotbe measured with the 168-7721 Ultrasonic WearIndicator III, provisions have been made for storingthe required conventional CTS tools in the carryingcase. These tools are not provided with the group,but may be ordered separately.

NOTE: The part numbers for other conventionalundercarriage tools can be found in the CTSHandbook.

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-6000Paper Towel Case)

— NEEG2835 168-7720 Group Label (located in lid ofcarrying case)

— — Four 1-9/16 inch protective caps forRS232 connector

— NEHS0730 Ultrasonic Wear Indicator III Group ToolOperating Manual

Chart B.Storage Locations

Item Part No. Description

1 PEKP9400 Custom Track Service Handbook: Fitsunder Indicator III

2 5P-3277 Tape Measure: 3 mm (10 ft) for pitch, sag,and sprocket measurement

3 8H-8580 Scraper: For cleaning undercarriagecomponents

4 5P-8616 Sprocket Gauge: For D4, D5, and D6Track-type Tractors

5 5P-8617 Sprocket Gauge: For D7, D8, and D9Track-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 the168-7721 Ultrasonic Wear Indicator III.

NOTICE

DO NOT attempt to recharge alkaline batteriesusing the 4C-3024 Battery Charger.

Attempting to charge an alkaline battery canresult in damage to the 168-7721 UltrasonicWear Indicator III.

Place a piece of tape over the charge connector,to prevent charging, when using alkalinebatteries.

Illustration 5. 168-7721 Indicator III With 168-7722 ProbeInstalled In 9U-6175 Soft Protective Case.

6

Chart C.Optional Items

Item Part No. Description

1 4C-5488 Cable Assembly RS232 (PC AT Version):For connecting the 168-7721 to an IBMAT, 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 IBMXT, 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 modemwhich transfers data over telephone linesto a personal computer.

4 1U-7445 NiCad (Nickel Cadmium) RechargeableBattery: (size AA) 1 per package.

5 1U-9533 Alkaline Battery: Non-rechargeablebattery (size AA) 96 per package.

6 156-1077 Power Inverter: For powering the 168-7721 from 12VDC and includes batterycables and a cigarette lighter.

7 9U-6175 Soft Protective Case: For protecting the168-7721 during use.

— — Custom Track Service (CTS) softwareprogram for transferring storedmeasurements from the 168-7721 to anIBM PC, or compatible, computer forstorage or printing. Also required when amodem is used.

— — Additional Service Replacement Part (notshown).

— 4C-5490 Couplant Holder: The servicereplacement for the holder that stores the9U-7981 Couplant container.

168-7720 Ultrasonic WearIndicator III GroupSpecificationsPower Supplied By 5 NiCad (Nickel Cadmium),

rechargeable batteries (size AA) or non-rechargeable1U-9533 Alkaline Batteries.

NOTE: The five AA batteries are accessed byremoving the Indicator III’s back cover. SeeReplacing the Internal Rechargeable Batteriessection for the procedure.

NOTICE

DO NOT attempt to recharge alkaline batteriesusing the 4C-3024 Battery Charger.

Attempting to charge an alkaline battery canresult in damage to the 168-7721 UltrasonicWear Indicator III.

Place a piece of tape over the charge connector,to prevent charging, when using alkalinebatteries.

Approximate Battery Life (with Indicator III’sbacklight OFF and beeper ON).NiCad Rechargeable . . . . . . . . . . . . . . . 19 HoursAlkaline Non-rechargeable . . . . . . . . . . . 47 Hours

Approximate Battery Life (with Indicator III’sbacklight and beeper ON).NiCad Rechargeable . . . . . . . . . . . . . . . 14 HoursAlkaline 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 . . . . . . . . . . -18°C to 60°C(O°F to 140°F)

Storage Temperature:Without Batteries Installed . . . . . . . . -40°C to 60°C(-40°F to 140°F)

With Alkaline Batteries Installed . . . -40°C to 50°C(less than 6 months) (-40°F to 125°F)

With NiCad Batteries Installed . . . . -20°C to 45°C(less than 6 months) (-4°F to 113°F)

Memory Size:Flash Memory . . . . . . . . . . . . . . . . . . 32,768 BytesRandom Access Memory (RAM) . . . . . 1024 BytesElectrically Erasable Memory . . . . . . 49,830 Bytes

RS232 Specifications . . . . 1200, 9600 (default), or19,200 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 ProbeSpecificationsProbe Type . . . . . . Dual Element 7.5 MHz special

applicationProbe Size:Measuring Surface Diameter . . . . . 11 mm (.43 in)Length . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.65 in)Diameter . . . . . . . . . . . . . . . . . . . . 19 mm (.748 in)

Allowable Surface Temperature . . -18°C to 150°C (0°F to 300°F)

Cable Length . . . . . . . . . . . . . . . . 1524 mm (60 in)

Includes Certificate of Conformity

7

156-1077 Power InverterSpecificationsInput Voltage Range . . . . . . . . . . 10.5 to 14.5 VDCInput 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 . . . . 10°C to 26.7°C(50°F to 80°F)

Over Temperature Protection . . . . When the powerinverters internal heat sinks reach 65.5°C (150°F),

the inverter will automatically shut down. Theinverter may be “restarted” by first disconnectingthe 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 automaticallyshuts down if continuous power

is greater than 300 Watts

Connections to the 168-7721Indicator III

Illustration 6. Connectors For 168-7721.Refer to Chart C for item identification.

8

Chart D.Connectors For 168-7721 Indicator III

Item Part No. Description

1 9U-7981 CouplantStored in pump-type dispenser. A smallamount of couplant must be applied tothe sensing end of the 168-7722Ultrasonic Probe, before measuring, tocouple ultrasonic sound into the materialbeing measured.

2 4C-5490 HolderUsed to hold the 9U-7981 CouplantDispenser

3 — Steel Calibration DiskThe disk is used to check the accuracy ofthe wear indicator and recalibrate thewear indicator, if necessary. Foradditional information, refer to Calibratingthe Ultrasonic Wear Indicator III in thismanual.

4 RS232 Connector (shown without 1 9/16”protective cap installed)Used to connect4C-5488 Cable As. RS232 (PC AT) or4C-5489 Cable As. RS232 (PC XT) or4C-5897 Cable As. RS232 (Modem Cable)These cables can be used to transferstored undercarriage data from the 168-7721 to a personal computer orprinter. Refer to Optional Items in thismanual, for each cables specific functionand software program requirements.

5 — Charger ConnectorUsed to connect the Battery Chargerwhen recharging the rechargeableBatteries (NiCad). Also used to power the 168-7721 with the 4C-3024 BatteryCharger. The plug of the 4C-4032 can beplugged into the 156-1077 Power Inverterto provide 12 VDC power for powering theindicator.

6 Probe ConnectorUsed to install the 168-7722 or 4C-5485Ultrasonic Probe.

7 — Earphone Connector (mono)Used to connect earphone to hearbeeper’s sound in noisy environments.The beeper can only be heard when anearphone jack is installed in the earphoneconnector.

168-7721 Indicator IIIDescription

Illustration 7. Indicator III Front Panel And Key Pad.

Abbreviations and DescriptionsUsed on Front Panel and Key Pad1. MACH:

Machine, referred to as MACH(ine) in thismanual.

2. 6.3 mm (.25 in):Describes the metal calibration disk’s thicknessmeasured in millimeters and inches duringprobe calibration (metal calibration disk islocated on top panel).

3. RS232:Identifies connector located on top panel whichprovides the RS232 signal connection, for theoptional cables, for transferring data to apersonal computer. Refer to Optional Items (in this manual) for each cables specificfunction, software program requirements, anduse 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 toppanel, for the 168-7722 or 4C-5485 UltrasonicProbe.

6. LOCATION & LOC:Location, referred to as LOC(ation) in thismanual. Refers to undercarriage data locations.

Description of Displays and Keys7. 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 bygoing to this machine number.

8. LOCATION Display:Shows the undercarriage storage LOC(ation)display selected by the up or down arrow keysand shows the machine model when in theMACH(ine) mode of operation.The display, in Illustration 7, is in the LOC(ation)mode.

9. MEASURED VALUE:Displays the thickness value being measured orthe value of the last measurement taken.MM or IN will appear to the right of the valuedisplayed, when measuring, to show the probeis properly coupled to the material.

10. MEMORY VALUE:Displays the stored value for the locationshown under MACH and LOCATION when inthe LOC(ation) mode of operation.The machine serial (product identification)number is displayed here when in theMACH(ine) mode of operation.

9

11. SAVE/SET:This key will provide one of two functions:

SAVE:Press to store the MEASURED VALUE in theMEMORY VALUE location. After the value issaved, the display will automatically advanceto the next LOCATION.

SET: Press and release the blue SHIFT key and thenthe SET key to enter the Setting Menu.Perform the same keystrokes to exit theSettings Menu.

12. MM/IN:Changes the display values from MM(millimeter) to IN (inch) and will work only whena value is on the display. Also used to showultrasonic velocity. Refer to Ultrasonic Velocityin this manual.

13. PROBE CAL:Calibrates the ultrasonic probe so the IndicatorIII will read accurately.

To use, apply couplant to the sensing end ofthe probe and press probe to the metalcalibration disk on top of the Indicator III.

If the MEASURED VALUE display is not 6.3 mmor (.25 in) while in the Low Resolution mode,press PROBE CAL while holding the probe onthe disk and it should read correctly.

If the MEASURED VALUE display is not in therange of 6.25 to 6.32 mm or (.246 to .249 in)while in the High Resolution mode, pressPROBE CAL while holding the probe on thedisk and it should read correctly.

Refer to Calibrating the Ultrasonic WearIndicator III and Checking the UltrasonicVelocity in this manual.

14. ON/OFF:Turns Indicator III ON or OFF.

Indicator III will automatically turn OFF after 5minutes if not in use. This function can bedisabled in the Settings Menu. Refer toSettings Menu in this manual.

15. CLR/CLR MACH:This key will provide one of two functions:

CLR will erase the character under the flashingcursor in the LOC(ation) mode.

CLR MACH clears all MEMORY VALUEinformation from storage for the MACH(ine)number shown on the display or ALL 64MACHINES.

NOTE: Press and release the red SHIFT key andthen CLR MACH key to enter the CLR MACHscreen. The top line of the display will show CLRMACH and then the number of the machine to becleared. Press the VALUE key to clear thismachine. To clear all machines, first press the upor down arrow key to move the cursor to the bottomline of the display showing CLR ALL MACH. Pressthe VALUE key.

16. LOC/MACH:Changes from the MACH(ine) mode to theLOC(ation) mode of operation. In theMACH(ine) mode, the LOCATION display willshow the letters MACH.

Use the up or down arrow keys to move to anyof the 64 machine storage locations.

In the LOC(ation) mode, the LOCATIONdisplay does not show the letters MACH, butinstead describes the inspection information orundercarriage measurement location.

Use the up or down arrow keys to move to anyof the individual measurement locations for theMACH(ine) number shown in the upper left ofthe display.

17. Left Arrow, A or B:This key will provide one of two functions:

In the LOC(ation) mode, the flashing cursor ismoved one position to the left for each keypress.

When preceded by pressing either the red orblue SHIFT key, the corresponding coloredcharacter is entered on the display.

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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 nextMACH(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 nextmeasurement location. This is the LOC(ation)mode of operation.

Hold the up arrow key to scroll in theMACH(ine) or LOC(ation) Display Mode.

BACKLIGHT:Press and release the blue SHIFT key, thenpress this key to turn ON the display’sbacklight. Perform the same keystrokes to turnthe backlight OFF.

NOTE: When Ultrasonic Wear Indicator III is inManual Turnoff mode (selectable in the settingsmenu): If backlight is ON, no key has beenpressed, and probe not coupled for 5 minutes, thenthe backlight will turn OFF. The backlight willautomatically turn ON when a key is pressed orprobe is coupled.

19. DOWN ARROW:Use to move the display in the oppositedirection as the up arrow.

NOTE: Arrow keys will change display once everytime 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 whenin the LOC(ation) mode. When pressed, a digiton 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 rightone character for each key press.

NOTE: Pressing and holding this key will scroll theflashing cursor at a faster rate.

21. SHIFT (blue):Used to enter any blue character from the keypad.

22. SHIFT (red):Used to enter any red character from the keypad.

NOTE: The SHIFT keys are to be pressed andreleased before pressing the desired character key.

23. Alphanumeric keys:These keys are used to enter directly, into thedisplay, any information the user wishes toenter into storage when in the LOC(ation)mode.

11

Charging the Internal NiCad(rechargeable) BatteriesThe 168-7720 Ultrasonic Wear Indicator III Group issupplied with a 4C-3024 Battery Charger (1) andfive NiCad (Nickel Cadmium), RechargeableBatteries, (size AA).

The batteries must be charged before using the168-7720 Ultrasonic Wear Indicator III Group.

Illustration 8. Rear View Of 4C-3024 Battery Charger.

Procedure1. Move switch (1) on the rear of 4C-3024 Battery

Charger (2) to the correct AC line voltage, either120 Volts or 230 Volts, depending on use.

2. Connect charger connector (3) into theCHARGE connector located on the top of theIndicator III.

3. Plug power supply end (4) into an AC outlet.

NOTE: For operation outside the USA, an ACpower plug adapter may be required.

4. Turn the Indicator III ON to check if the batteriesare being charged. It may be necessary to waita few minutes until the batteries are sufficientlycharged to operate the Indicator III.

5. When first turned ON, the display may flash,indicating low voltage. The flashing should stopafter a few minutes as the batteries arecharged.

6. Turn the Indicator III OFF and leave the chargerON for 10 to 14 hours.

NOTE: The Indicator III will not be damaged if thecharger is left on for longer time periods.

NOTE: For maximum battery life, recharge onlyafter the display flashes or goes blank, indicatingthe batteries are near or fully discharged.

Replacing the InternalRechargeable BatteriesThe 168-7721 Ultrasonic Wear Indicator III issupplied with five NiCad (Nickel Cadmium),rechargeable batteries (size AA).

These can be replaced with new 1U-7445 Batterieswhen 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 removedindefinitely and the internal memory values will notbe affected.

NOTICE

DO NOT attempt to recharge alkaline batteriesusing the 4C-3024 Battery Charger.

Attempting to charge an alkaline battery canresult in damage to the 168-7721 UltrasonicWear Indicator III.

Place a piece of tape over the charge connector,to prevent charging, when using alkalinebatteries.

Illustration 9. Back View Of 168-7721 Ultrasonic WearIndicator 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 newbatteries.

4. To install new batteries: The (+) terminal of thebattery must be placed on the battery contactwith the (+) symbol (4) (in the recessed area ofthe battery compartment, as shown inIllustration 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 placethe (–) terminal of one battery against one of thenegative battery contacts (does not have a (+) signby it inside of the battery compartment (5).Compress the negative battery contact as much aspossible (see Illustration 13) and then install theplus terminal (+) of the battery into the batterycompartment.

Illustration 13. Installing Battery Cover.(5) Battery (–) negative terminal. (6) Battery (+) positiveterminal.

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

13

Connecting to DC Power1. The optional 156-1077 Power Inverter (12 VDC)

may be used to connect the 168-7721 Indicatorto an external DC power source.

2. Plug the power plug of the 4C-3024 BatteryCharger 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 orengine as the power source, power the emissionanalyzer by connecting the power cable clipwith the black colored handle to the machine orengines frame or to the battery's negativeterminal. Connect the power cable clip with thered colored handle to the battery's positiveterminal.

NOTICE

The 156-1077 Power Inverter requires a 12 VDCinput. Make sure not to exceed this specificationor the power inverter's fuse may blow resultingin possible damage to the power inverter. Also,reverse polarity could damage the powerinverter, but will most likely blow the 35 Amperefuse. Refer to item 5, illustration 9.

4. The 168-7721 Indicator can also be powered bya vehicle's 12 VDC cigarette lighter. Removethe cable with the power clips from the powerinverter. The power inverter can now beplugged 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 thataccept the power cable's plug supplied with theemission analyzer. (8) ON/OFF switch.

14

Care and Cleaning of 168-7721Indicator IIIThe 168-7721 Ultrasonic Wear Indicator III is adurable hand-held instrument. However, since itwill 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, andthe instrument can be damaged if water is allowedto 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 allowit to dry completely in a warm, dry area.

Keep the Indicator III stored in the carrying casewhen not in use.

Removing the 9U-7981 CouplantResidue

When taking measurements, all excess 9U-7981Couplant residue should be removed from theprobe, Indicator III, and case with paper towelsbefore the residue dries.

The couplant is water soluble and a damp clothcan be used to remove any residue that has dried.However, care must be taken so no water entersthe Indicator III case.

Cleaning the Case and Front Panel Key Pad

NOTICE

Do not use aromatic hydrocarbons orchlorinated solvents for cleaning. Thesechemicals will react with the plastics used in thecase and cause damage.

Care of Connectors

The RS232 and PROBE connectors, on the end ofthe Indicator III, must be kept clean. Allowing dirtto enter the contacts can cause interference andkeep the mating connectors from plugging in ormaking proper contact.

During use, the PROBE connector is protected bythe probe cable connector. Leave the probeconnected during storage so dirt does not enter.

The RS232 connector is shipped with a plastic capon it. Keep this cap in place at all times when thisconnector is not being used. Extra plastic caps areincluded with the group.

15

Operating Instructions for168-7721 Indicator IIIPlug the connector on the end of the 168-7722 or4C-5485 Ultrasonic Probe Cable into the probeconnector 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 ashort time, then automatically change to aMACH (machine) display similar to those shownbelow.

MACH Display (memory clear).

3. The MACH number (in the upper left handcorner of the display) will be the one in usewhen the instrument was last turned OFF.If internal memory for the machine numbershown is clear (contains no stored information),it will appear as the MACH display, as shown inStep 2.

MACH Display (last machine used).

4. The example, in step 3, shows the MACHdisplay with the model and serial (productidentification) number of the last machine usedshown.The MACH(ine) number may be selected withthe up arrow or down arrow keys.

NOTE: If the MACH(ine) number will not change:Press the LOC/MACH key to get to the MACHdisplay as shown above. Then use the up arrow ordown arrow keys again.

Calibrating the Indicator III and Probe

Before taking measurements, the accuracy of theIndicator III and probe must be checked and theIndicator III and probe recalibrated, if needed.

This procedure should be performed at the start ofeach day and anytime the accuracy is in questionto ensure the readings taken will be accurate.

Once the Indicator III and probe are calibrated withthis procedure, it will ONLY be accurate formeasuring undercarriage steel or steel of a similartype.

If other materials are measured, the velocity mustbe changed and a different PROBE CAL valueused. Refer to Ultrasonic Velocity Adjustment inthis 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 ProbeBeing Calibrated.

A metal calibration disk, Illustration 16, is used tocheck the accuracy and calibrate the Indicator IIIand probe.

1. Place a small amount of 9U-7981 Couplant onthe sensing end of the probe.See Illustration 15.

2. Press the probe against the metal calibrationdisk on the top of the Indicator III.See Illustration 16.

3. A number will appear at the MEASURED VALUEdisplay. If the probe is properly coupled to thedisk, the MM or IN indicator will also bedisplayed. Also, a beeping sound will be heard(if not turned OFF using the Settings menu) toindicate 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 andthe 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 notcorrect, as shown in step 3, follow theinstructions in Step 6.

Probe Removed From Calibration Disk.

5. If the calibration is correct, as shown in step 4,proceed to the Undercarriage MeasurementProcedure section.

6. To calibrate the Indicator III and probe, pressthe PROBE CAL key. The display should nowshow (PROBE).

PROBE CAL Key Pressed.

7. Place a small amount of the 9U-7981 Couplanton the sensing end of the probe. Press theprobe to the metal calibration disk.See Illustration 16.

Calibration Complete.

8. The MEASURED VALUE, shown in step 7,should now be correct. If not, repeat thisprocedure until it is correct.

9. Once the correct value appears, the wearindicator is ready to use.

NOTE: An alternate method of calibration is topress the PROBE CAL key while holding the probeon the disk. If the Indicator III still will not calibratecorrectly, check for the proper velocity setting forundercarriage steel. Refer to Ultrasonic VelocityAdjustment in this manual.

15 MACH (CLEAR)0.24 IN

(PROBE)

15 MACH (CLEAR)0.25

15 MACH (CLEAR)0.24 IN

17

Undercarriage MeasurementProcedureNOTE: When using this procedure, refer to theUndercarriage Measurement Display Map in thismanual, for additional information on the sequenceof the displays.

1. The Indicator III MUST be calibrated before anymeasurements are taken. Refer to Calibratingthe Ultrasonic Wear Indicator III section.

2. After calibration, use the up or down arrow keysto select a (CLEAR) machine or to locate thespecific machine you are measuring.

Clearing the Memory1. If a (CLEAR) machine cannot be located, any

one or all machine(s) can be cleared by firstpressing and releasing the red SHIFT key andthen 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 thedisplay for a short period of time.

3. The (CLEAR) message indicates the memoryhas been cleared and is ready for new data.

NOTE: When a MACH memory is cleared, the datathat was in the memory for that MACH number willbe lost and cannot be retrieved.

MACH Display After Clearing Machine Memory.

4. To clear all machines, first press the up or downarrow key to move the cursor to the bottom lineof 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 hasbeen cleared and is ready for new data.

Using LOC(ation) Mode ofOperationTo store ultrasonic measurements and inputinformation about the machine being measured, theIndicator III must be in the LOC(ation) mode ofoperation.

To change to the LOC(ation) mode from theMACH(ine) mode, press the LOC/MACH key. Thiskey always changes the display to the other modeof operation. If the word MACH is not on thedisplay, the Indicator III is in the LOC(ation) mode.

Once in the LOC(ation) mode, the 71 differentundercarriage storage locations shown in the “List of Undercarriage Storage LOC(ation)Displays” are available for use. These storagelocations can be accessed with the up and downarrow keys. Refer to the UndercarriageMeasurement Display Map in this manual foradditional information on how to change betweenthe various displays.

CLR ALL MACH

2 MACH (CLEAR)

CLR MACH 2

CLR MACH 2CLR ALL MACH

18

List of Undercarriage StorageLOC(ation) Displays

NOTE: The Setting Menu is used to change howthe Date (location 3), the Distance (location 6), andthe Distance per Week (location 7) are displayed.

19

Loc. Display Notes

1 MODEL The machine model number2 SERIAL NUMBER The machine serial number3 DATE MM/DD/YYYY The date by month, day, year

DATE DD/MM/YYYY The date by day, month, year4 HOURS The service hour meter reading

on the machine5 HRS. / WEEK The number of hours the

machine has worked per week6 MILES The reading on the machine’s

KM odometer in miles or kilometers7 MILES/WEEK The distance the machine has

KM/WEEK traveled per week8 JOB SITE The location of the machine9 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 ConditionsPacking, use SET DIGIT:MODERATE, HIGH. LOW

13 BUSHING ALLOW Bushing allowable wear, use SETDIGIT: GREATER, LESSER

14 L TRACK SAG Left track sag - use SET DIGIT15 L DRY JOINTS Left dry joints - use SET DIGIT16 L LINK Left link measurement17 L BUSH INT Left bushing internal wear - use

SET DIGIT18 L BUSHING EXT Left bushing external wear19 BUSHING TOOL Measuring tool used on bushings

(EXT). SET DIGIT: ULTRASONIC,CALIPER, DEPTH GAUGE

20 L SHOE Left shoe measurement21 SHOE TOOL Measurement tool used on

shoes, SET DIGIT:ULTRASONIC, DEPTH GAUGE

22 F IDLER DEPTH Front idler depth gaugemeasurement - use SET DIGIT

23 F IDLER SONIC Front idler ultrasonicmeasurement - use SET DIGIT

24 R IDLER DEPTH Rear idler depth gauge meas.25 R IDLER SONIC Rear idler ultrasonic measurement26 L CAR. ROLL 1 Left carrier roller number 127 L CAR. ROLL 2 Left carrier roller number 228 L CAR. ROLL 3 Left carrier roller number 329 CAR ROLL TOOL Measuring tool used on carrier

rollers. SET DIGIT:ULTRASONIC, CALIPER

30 L ROLLER 1 Left track roller number 131 L ROLLER 2 Left track roller number 232 L ROLLER 3 Left track roller number 333 L ROLLER 4 Left track roller number 434 L ROLLER 5 Left track roller number 5

Loc. Display Notes

35 L ROLLER 6 Left track roller number 636 L ROLLER 7 Left track roller number 737 L ROLLER 8 Left track roller number 838 L ROLLER 9 Left track roller number 939 L ROLLER 10 Left track roller number 1040 ROLLER TOOL Measuring tool used on track

rollers. SET DIGIT:ULTRASONIC, CALIPER, DEPTHGAUGE

41 L SPROCKET Left sprocket - use SET DIGIT42 R TRACK SAG Right track sag - use SET DIGIT43 R DRY JOINTS Right dry joints - use SET DIGIT44 A LINK Right link measurement45 A BUSHING INT Right bushing internal wear -

use SET DIGIT46 A BUSHING EXT Right bushing external wear47 R SHOE Right shoe measurement48 F IDLER DEPTH Front idler depth gauge

measurement - use SET DIGIT49 F IDLER SONIC Front idler ultrasonic

measurement50 R IDLER DEPTH Rear idler depth gauge

measurement - use SET DIGIT51 R IDLER SONIC Rear idler ultrasonic

measurement52 A CAR. ROLL 1 Right carrier roller number 153 R CAR. ROLL 2 Right carrier roller number 254 A CAR. ROLL 3 Right carrier roller number 355 A ROLLER 1 Right track roller number 156 R ROLLER 2 Right track roller number 257 R ROLLER 3 Right track roller number 358 R ROLLER 4 Right track roller number 459 R ROLLER 5 Right track roller number 560 A ROLLER 6 Right track roller number 661 R ROLLER 7 Right track roller number 762 R ROLLER 8 Right track roller number 863 R ROLLER 9 Right track roller number 964 R ROLLER 10 Right track roller number 1065 R SPROCKET Right sprocket - use SET DIGIT66 NOTES LINE 1 16 characters - use SET DIGIT67 NOTES LINE 2 16 characters - use SET DIGIT68 NOTES LINE 3 16 characters - use SET DIGIT69 NOTES LINE 4 16 characters - use SET DIGIT70 SPARE #1 For extra measurement71 SPARE #2 For extra measurement

MODEL display with empty MODEL number.

MODEL display containing MODEL number.

The first storage location is MODEL. This display isshown above in the way it appears with and withouta model number in memory. The machine modelnumber can be entered where the dotted line is ora number already shown can be changed. Thisdisplay will always be the first display shown whenswitching from the MACH(ine) to LOC(ation) modeof operation.

Entering Information into theIndicator IIIIf the memory contains a MODEL number, it willalways be shown on the display. If it does notcontain a MODEL number, dashed lines will showwhere the number should be entered.

To enter the MODEL, press the VALUE key and thefirst number digit location will become a blinkingbox. Whenever a blinking box is on the display,numbers or alphabetical characters may beentered directly using the keys on the front panel.

To enter the red characters, the red SHIFT key mustbe pressed and released before the character keyis pressed.

To enter a blue character, the blue SHIFT key mustbe pressed and released before the character keyis pressed.

Continue this procedure until the entire MODELnumber is on the display. When finished, press theSAVE key and the MODEL number will be stored inmemory.

After SAVE is pressed, the Indicator III will advancethe display to the next LOC(ation) display, which isthe SERIAL NUMBER.

To enter the serial (product identification) numberinto the SERIAL NUMBER display, follow the sameprocedure as used in the Using LOC(ation) Modeof Operation section.

Up to 16 numbers or letters in any combination canbe entered as the serial number on the blanksprovided. If the serial number does not fill all theblanks, the serial number will be moved to the rightof 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 WordsThe LOC(ation) displays for underfoot conditions(IMPACT), bushing allowable wear (BUSHINGALLOW), and measurement tool used (BUSHINGTOOL or SHOE TOOL) have words in them.

Example of IMPACT with alternate wordMODERATE.

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 VALUEkey. The other words will appear, as shown in theprevious examples.

To select and store the desired word in the memory,leave it on the display and press the up arrow keyto move on to the next location. The selected wordwill always reappear on the display when thatdisplay is used again.

Measuring Track SagThe first display for a measurement is L TRACKSAG (left track sag). This measurement cannot betaken with the Indicator III. It must be takenaccording to the instructions in the CTS handbookwith a tape measure and manually entered into theIndicator III’s memory.

1. To enter this measurement at the L TRACK SAGdisplay, press the VALUE key.

2. The first digit of the MEMORY VALUE will flash,allowing the measurement to be entered. Referto the topic Entering Information into theUltrasonic Wear Indicator III section.

3. When the proper number has been entered,press the SAVE key to continue with the nextreading.

Taking Ultrasonic MeasurementsThe next LOC(ation) is L LINK (left linkmeasurement) and is the first measurement to betaken with the ultrasonic probe.

NOTE: Refer to the Undercarriage MeasurementTechniques section, in this manual, for details onhow to measure each undercarriage component.

1. To take a measurement, place a small amount of9U-7981 Couplant on the sensing end of theprobe and press it firmly and squarely againstthe wear surface.

2. The measurement will appear on the displayabove MEASURED VALUE.

3. An indication of proper coupling of the probe isshown by IN or MM appearing after theMEASURED VALUE. Also, a beeping sound willbe heard (if not turned OFF using the Settingsmenu) to indicate good coupling.

NOTE: The thickness value and its units (i.e. 4.92 IN) flash while the probe is coupled andthe beeping sound occurs at the same rate.

4. When you are satisfied a good value is on thedisplay, remove the probe and that value willremain in the MEASURED VALUE display.

NOTE: Measurements can only be taken in theMACH(ine) Display Mode or in a LOC(ation)Display Mode’s screen that accepts ultrasonicmeasurements.

Saving Measured Values inMemoryThe measured value shown on the display can besaved in the memory of the wear indicator bypressing the SAVE key. After a (SAVE) indicationhas flashed on the display, the next undercarriagepart to be measured will automatically appear onthe display.

To make sure that the number was recordedcorrectly, press the down arrow key to go back tothe previous LOCATION. The value just measuredwill show on the MEMORY VALUE display.

NOTE: While taking an ultrasonic measurement,once satisfied of a good measurement, press theSAVE key before removing the probe.

Tool DisplaysSome displays refer to the type of tool used formeasurement of the component described.

If a tool other than the ultrasonic is used tomeasure the component, the correct tool must beselected. This is needed to indicate which wearcharts should be used. An example is theBUSHING TOOL display as shown below:

Example of BUSHING TOOL with type of tool used:ULTRASONIC

Example of BUSHING TOOL with type of tool used:CALIPER

Example of BUSHING TOOL with type of tool used:DEPTH GAUGE

1 BUSHING TOOL3 DEPTH GAUGE

1 BUSHING TOOL2 CALIPER

1 BUSHING TOOL1 ULTRASONIC

21

Pressing the VALUE key will select CALIPER orDEPTH GAUGE. Select the tool to be used andthen press the up arrow key to move to the nextdisplay and the selected tool will be put in memory.

Continue through the LOCATION displays until allof the undercarriage measurements have beentaken and recorded.

Spaces for notes and two extra measurementstorage locations have been provided at the end ofthe measurement sequence.

When finished with the measurements, advance tothe next machine by pressing LOC/MACH and theup arrow key.

Measurement Operating TipsThe following operating tips will make it easier totake measurements with the Indicator III.

1. The sequence of the undercarriage storagelocations were selected to easily transfer intothe Custom Track Service personal computerprogram. Until you have this program, it maysave time to enter and save only the serialnumber and measurements in the Indicator III.Then manually record the data for locations 2through 13 directly on the CTS Form. Refer tothe topic entitled List of Undercarriage StorageLocation Displays section.After taking the measurements, scroll throughthe stored measurements while manuallyrecording them on the CTS form.

2. When using the arrow keys, press and releasethe keys to change the display slowly, or holdthe key down to scroll rapidly.

3. For users preferring not to use the memoryfeature, ultrasonic measurements can be takenat any time regardless of the LOC(ation) orMACH(ine) settings.When taking measurements, the 9U-7981Couplant must be applied to the sensing end ofthe probe before measuring a component.

4. To couple the ultrasonic probe to a component,it is important to have the 9U-7981 Couplantbetween the sensing end of the probe and thecomponent. The probe tip surface must be flat(square) with the part being measured. It maybe easier to hold the probe properly if a finger isheld on top of the probe.

5. When taking ultrasonic measurements, keep inmind the first reading displayed may not be thebest measurement. Always move the probearound the part surface to find the smallest, ormost worn measurement.

6. Saving ultrasonic measurements can be doneeither while holding the probe on the part orafter removing the probe. If you prefer toremove the probe before pressing SAVE, pullthe probe off quickly to prevent themeasurement from increasing slightly as theprobe is removed.

22

Undercarriage MeasurementTechniques

Track Links

Illustration 17. Measuring Track Links.

1. Measure distance from tread surface to bushingbore.

2. Place probe over the center line of the bushing.

3. Slide the probe along the tread surface andtake the smallest reading.

Track Shoes

Illustration 18. Probe Located On The Bottom Of ThePlate.

1. Measure the distance from the bottom of theplate to tip of the grouser.

Illustration 19. Probe Located On The Tip Of TheGrouser.

2. It may be easier to measure from the tip of thegrouser to the bottom of the plate.

3. On double grouser and triple grouser shoes, donot measure the rear grouser due tointerference with the trailing edge.

4. On regrousered shoes, it may be necessary touse a depth gauge or take ultrasonicmeasurements from the tip and the bottom ofthe plate and add the readings together, sincethe weld does not completely penetrate.

Track Bushing

Illustration 20.

1. Measure the wall thickness.

2. Slowly slide the probe around the reverse driveside to find the smallest dimension and savethis measurement.

3. Next, slide the probe around the vertical andforward drive sides to check if the measurementis smaller (indicating more worn). Always savethe smallest measurement.

23

Idler

Illustration 21.

1. Measure the center flange thickness only onfabricated idlers. Determine center flange wearfrom the idler wear charts in the CTS Handbook.

2. Use conventional depth gauge to measure wearon the tread surface.

3. Add center flange wear to the depth gaugemeasurement 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 OfTread Surface To The Bore.

NOTE: Due to the use of tapered roller bearings,more than one thickness can be found along eachtread surface.

It is important to place the probe on the outer halfof the tread surface on the side of the rolleropposite the shaft.

NOTE: The Ultrasonic Wear Indicator III will notmeasure cast iron rollers. Some D3, D4, D5, andD6 Tractors or 225 Excavator carrier rollers are cast iron.

24

Track Roller

Illustration 25.

1. Measure the distance from the tread surface tothe bore.

2. Do not measure to the retainer bolt holes on H, N, and L series Track-Type Tractors andcurrent Track-Type Loaders. Observe thelocation of the retainer bolts and place theprobe between them. On low sprocket Track-Type Tractors, earlier Type Loaders, andExcavators the retainer bolts are not visible.Observe the thickness measured value closelyfrom roller to roller to catch any abnormallysmall thickness which would indicate a readingto the bolt hole.

3. On track rollers with noticeable cusp wear, slidethe probe along the cusp to get the smallestreadings. To speed the process, select thecusp that normally is most worn (the cuspcloser to the center of the roller), rather thansliding the probe over both cusps each time.

Competitive PartsDo not measure competitive undercarriages withthe Indicator III. The internal dimensions of theseparts will likely be different than on the Catdesigned parts, resulting in incorrect percent wornreadings.

Measuring the Thickness of PartsOther than UndercarriageIn addition to measuring undercarriage wear, theUltrasonic Wear Indicator III can be used tomeasure steel part thickness without changing anysettings. This is simple to do because the wearindicator is designed to always show theMEASURED VALUE regardless of which keys havebeen pressed. This allows a nonexperiencedperson to take readings.

Examples where this may be used are to check thewall thickness of a:

•• Bulldozer blade

•• Bucket base edge

•• Scraper bowl

NOTE: In addition to measuring steel parts, manyother materials can be measured. However, toaccurately measure these materials, the velocitysetting of the Indicator III must be changed. Referto the Ultrasonic Velocity Adjustment section in thismanual for complete information on measuringmaterials other than steel.

1. Install 168-7722 or 4C-5485 Probe, andcalibrate the Indicator III and probe. Refer toUltrasonic Velocity Adjustment in this manual.When taking measurements, the 9U-7981Couplant must be applied to the sensing end ofthe probe before measuring.

2. To take a reading, apply a small amount ofcouplant on the sensing end of the probe andpress the probe onto the surface to bemeasured. The thickness of the material will beshown at MEASURED VALUE on the display.Whenever the probe is properly coupled, eitherIN or MM will show on the display. Also, asteady beeping sound will be heard (if notturned OFF in the Settings Menu). When theprobe is removed from the material, the lastreading will remain on the display.

3. To check the accuracy of the reading, measurea piece of the same type of material of knownthickness. If the reading is not correct, thevelocity may be adjusted to make the Indicator III read accurate. Refer to UltrasonicVelocity Adjustment in this manual.

25

Transferring the MemoryValues to or From a ComputerThe information contained (saved) in theIndicator III’s memory may be transferred to an IBMor compatible personal computer for storage orprinting using the Custom Track Service (CTS)personal computer program.

When transferring machine data from an IBM orcompatible personal computer using the CustomTrack Service (CTS) program:

1. The Indicator III does not clear all 64 machinesbefore transferring new machine data from thePC. The CLR ALL MACH function may be usedto manually clear all 64 machines before thetransfer.

2. The user can select where the machine’s datawill be stored in the Indicator III by scrolling tothe Machine No. before the transfer. TheIndicator III will then store the transferred datafrom the machine(s) beginning with theMACH(ine) No. shown on the Indicator III’sdisplay.

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 willresult in the new machine data being storedbeginning with the Machine No. 1 instead of theMACH(ine) No. currently shown on the screen.

NOTE: When transferring machine data from a PCto the Indicator III, the Indicator III does not wraparound the 64 MACH(ine) locations, i.e. the datafrom 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. Thefirst machine transferred will be stored inMACH(ine) 63, the second machine transferred willbe stored in MACH(ine) 64, and the third machinewill overwrite the second machine and be stored inMACH(ine) 64.

Settings MenuThe Settings Menu is a special menu to changespecific functions for the wear indicator. Enter theSettings Menu by pressing and releasing the blue“SHIFT” key and then pressing the “SAVE/SET” key.The Settings Menu flow chart is shown asillustration 26. The Settings Menu contains thesefunctions in this order: Resolution, Turnoff, Velocity,Serial, Beeper, Language, Distance, and Date.Resolution is the first function displayed whenentering the Settings Menu. Press the up downarrow to scroll forward through the Settings Menuor up arrow to scroll backwards through theSettings Menu. Illustration 27 shows the differentsettings that can be selected with each function inthe Settings Menu.

Resolution

Allows the measurement resolution to be in a highor 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 byautomatically turning the Indicator III OFF if it hasnot been used for five minutes. Normal operationof the key pad ON/OFF switch is not affected.

1. MANUAL - Indicator III only turns OFF by usingthe "ON/OFF" key switch.

2. AUTO (default position) - Indicator IIIautomatically turns off after 5 minutes and nokeys have been pressed or the probe has notbeen coupled. The Indicator III will also turn offby using the "ON/OFF" key switch.

Velocity

Allows the ultrasonic velocity to be viewed on thedisplay and changed using the front panel keypad.

1. OFF - Velocity adjust disabled (default position).

2. ON - Velocity adjust enabled.

26

Serial

This function controls the speed (BAUD Rate) ofthe RS232 communications signal of transferringmemory values from the 168-7721 Ultrasonic WearIndicator III to a personal computer with CustomTrack Service software program installed ortransferring the memory values back to theIndicator III. The different BAUD Rates that areavailable are:

1. 1200.

2. 9600 (default position).

3. 19200.

Beeper

This function turns ON or OFF the beeper thatsounds when the probe is properly coupled to thematerial being measured. When turned OFF,coupling will still be indicated by MM or IN beingdisplayed beside the MEASURED VALUE whenproperly coupled.

1. ON (default position).

2. OFF.

Language

This function allows the language to be changed.All of these languages are in the 168-7721Ultrasonic 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 beselected:

1. MM/DD/YYYY - Month, Day, and Year (defaultsetting).

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)

ARROWKEYS

ARROWKEYS

ARROWKEYS

ARROWKEYS

ARROWKEYS

ARROWKEYS

ARROWKEYS

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 KEYVALUE KEY

TURNOFF AUTO

TURNOFF MANUAL

DEFAULT DEFAULT

VALUE KEYVALUE KEY

RESOLUTION 0.0MM [0.00IN]

RESOLUTION 0.00MM [0.000IN]

DEFAULT DEFAULT

VALUE KEYVALUE KEY

VELOCITY OFF

VELOCITY ON

BEEPER ON

BEEPER OFF

DEFAULT

VALUE KEY

SERIAL 9600

SERIAL 1200VALUE KEY

SERIAL 19200

VALUE KEY

DEFAULT

VALUE KEYVALUE KEY

LANGUAGE ENGLISH

VALUE KEYVALUE KEY

LANGUAGE

LANGUAGE FRENCH

LANGUAGE SPANISH

LANGUAGE GERMAN

LANGUAGE PORTUGUESE

VALUE KEY

VALUE KEY

0730-36

Ultrasonic VelocityAdjustmentAdjustment of the velocity calibrates the Indicator III so it can be used accurately tomeasure the thickness of materials other thanundercarriage steel.

Ultrasonic Velocity is the speed in Millimeters permicrosecond (MM/µSEC) or inches permicrosecond (IN/µSEC) that sound travels throughdifferent materials.

Refer to Chart E for a list of various materials,ultrasonic velocities, and probe calibration values.

1This is the value that will show at MEASUREDVALUE on the display when the metal calibrationdisk is measured for each velocity listed.

Checking the Ultrasonic Velocity1. Enter the Settings Menu and change the

VELOCITY from OFF to ON (refer to the SettingsMenu section).

2. With the Indicator III ON, make sure display is inthe MACH(ine) display mode, then press theMM/INCH key.

Example of Screen Display with VEL in MM/µSEC.

Example of Screen Display with VEL in IN/µSEC.

The velocity setting of the Indicator III will appearon the bottom line of the display, as shown above.Either MM or IN will be displayed, depending onwhich was being used earlier.

3. If the Indicator III is being used to measureUndercarriage Steel, be sure it reads 5.87 MM/µSEC or (.231 IN/µSEC), as shown in Step 2.

If the number is not correct, or you plan tomeasure other materials, the velocity numbercan be changed. Refer to the Changing theUltrasonic Velocity section.

Changing the Ultrasonic Velocity1. Locate the velocity number for the material to be

measured in Chart E. The numbers given inChart E are approximate, and slightly differentnumbers may have to be used to give accuratereadings because of differences in materialcomposition.

2. With the display showing the velocity, as shownin Step 2 in Checking the Ultrasonic Velocity,press the VALUE key. The first digit of thevelocity number will flash. Use the number keysto set the velocity to the desired number.

3. When the desired velocity number is shown onthe display, press the SAVE key and theIndicator III will now be set for the new material.

4. Calibrate the probe for this new material bypressing the PROBE CAL key. Then place theprobe, with couplant applied to the sensing endof the probe, on the calibration disk. Thenumber shown as the MEASURED VALUE onthe display should be the value shown on theVelocity chart under PROBE CAL. MEASUREDVALUE for the new material. Every time thecalibration disk is measured with this newvelocity setting, this reading should appear onthe MEASURED VALUE display instead of 6.3 mm or (.25 in).

5. Measure a known thickness of the new materialwith the Indicator III to be sure the readings areaccurate.

6. If the readings are not exact, change thevelocity setting number right-hand digit by oneand recalibrate.

7. Measure the material again and continue thisprocess until the Indicator III reads correctly.1 MACH (CLEAR)

VEL=.231 IN/USEC

1 MACH (CLEAR)VEL=5.87 MM/USEC

30

Chart E.

VelocityMM/µµEC Probe CAL1

Material (IN/µµSEC) 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 MonitorA Battery Level Monitor displays the estimatedbattery power remaining. Since many factorsinfluence the discharge rate, the battery levelmonitor is only an estimate of the remaining batterylife and should only be used as an estimate. TheBattery Level Monitor will show a percent valueranging from 0% to 100% in 10% increments.Monitor shows 100% when the battery voltage isgreater than or equal to 6.0 Volts. A value of 0%will be displayed anytime the battery voltage falls to5.4 Volts or less. The Battery Level Monitor screenwill appear as follows:

NOTE: If using NiCad rechargeable batteries, theymust be fully charged before each use for theBattery Level Monitor to work correctly. Refer toCharging the Internal NiCad (rechargeable)Batteries section.

Low Battery IndicationThe LCD display will flash for at least 30 secondswhen the battery voltage reaches 6.14 volts, whichis when a minimum of 2 hours of battery life is left.It will then stop flashing for a period of about thirtyminutes and return to at least a 30 second flashingperiod. When the Indicator III has reached aminimum of one hour of remaining battery life, thedisplay will flash and continue to flash until thepower is increased by charging the NiCad batteriesor installing new alkaline batteries. The Indicator IIIshuts down when the battery voltage reachesapproximately 5.12 volts.

NOTE: If using NiCad rechargeable batteries, theymust be fully charged before each use for the LowBattery Indication to work correctly. Refer toCharging the Internal NiCad (rechargeable)Batteries section.

NOTE: When the probe is coupled and theIndicator III’s battery power is low, the beepingsound will be heard at half rate. The beepingsound occurs when the entire display flashesduring 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 wasdisplayed when the Indicator III was last turnedOFF. If the Indicator III was turned OFF in theSettings Menu or showing the Battery Level Monitorscreen, then it will display the last MACH(ine) orLOC(ation) Display Mode screen when theIndicator III was last powered up. The Machine orLocation Display Mode screen will not beremembered if a factory reset was performed or ifthe Indicator III was abnormally powered down (i.e. by pulling batteries out while the Indicator IIIis ON).

Factory ResetThis function will reset the Indicator III back to thestate it was in when it left the factory. The reset willdestroy all stored data and completely reset allparameters in the Settings Menu to their defaultstates. To reset, the Indicator III must be OFF.Then, press and hold the "CLR" and "ON/OFF" keysat the same time for at least three seconds. TheIndicator III will turn ON and will display "FACTORYRESET" while the factory reset is being performed.

Viewing the Software VersionScreenThe version number of the software used in theUltrasonic Wear Indicator III can be viewed on thedisplay in the following manner.

1. Turn the Indicator III OFF.

2. Press and hold the LOC/MACH key, then pressON/OFF to turn the Indicator III ON.

Example of Screen Display for SOFTWAREVERSION number.

3. When the Indicator III comes ON, the SoftwareVersion screen is displayed, as shown in step 2.To leave this screen, turn the Indicator III OFF.The software is the program that operates themicroprocessor in the Indicator III. It iscontained nonvolatile, located in the Indicator III, so removing the batteries for anindefinite period of time will not affect thememory.

SOFTWARE VERSION3.1

BATTERY POWER70 PERCENT

31

Checking the Operation of theIndicator IIIThe following procedure may be used to check theoperation of the 168-7721 Ultrasonic Wear IndicatorIII and the 168-7722 or 4C-5485 Probe. The onlycomponents required for the test are the 168-7721Ultrasonic Wear Indicator III, 168-7722 or 4C-5485Probe, and 9U-7981 Couplant.

Perform all the procedures, as shown in OperatingInstructions for the 168-7721 Ultrasonic WearIndicator III, in this manual.

Instead of measuring undercarriage components,the metal calibration disk should be measured andthe MEASURED VALUE saved, and the MEMORYVALUE displayed to check for accurate readings.

Alternate Method

An alternate method is to measure a knownthickness of undercarriage steel.

1. Check the display of the undercarriage storagelocations for one machine. During this test, useall front panel keys to be sure they operatecorrectly.

If the Indicator III does not operate properlyduring this test, refer to the Troubleshootingsection in this manual.

2. Next, test the Indicator III on actualundercarriage components. Correctmeasurements should appear on theMEASURED VALUE display without having tomove the probe back and forth.

3. Also check to see that measurements can betaken on very thick undercarriage componentssuch as through track shoe grouser bars.

4. If the Indicator III has trouble making any ofthese readings, the gain may need to beadjusted. Refer to the Troubleshooting sectionin this manual for the procedures to adjust thegain.

5. This completes the test of the Indicator III.

Adjusting the Display'sContrastThe display's contrast may be adjusted to theuser's preference. The contrast has been set at thefactory. If it is determined it needs to be changed,use the following procedures:

1. Remove six screws from the back cover andremove the cover.

2. Locate contrast adjustment (Illustration 28) onthe top of the printed circuit board. It is one ofonly two screwdriver adjustments and is locatedbelow the calibration block and is labeled RP2on the printed circuit board.

3. Before turning this adjustment, observe theposition of the screwdriver slot to see if it ismarked. Place a mark on the small plastic caseif the position is not already marked. This is thefactory setting of the display's contrast.Marking this position will allow you to return it toits original setting, if desired.

4. To adjust the display's contrast, use a small flathead screwdriver to turn the contrast whileviewing the display's screen. Continue to adjustuntil the information on the screen is clear to theuser's preference. Once the setting is obtained,replace the rear cover.

Illustration 28. Cover removed to access the gain anddisplay's contrast adjustments.(1) RP1 Gain adjustment. (2) RP2 Display's contrastadjustment.

32

Adjusting the GainIf the gain is out of adjustment. it will result ininaccurate or hard to get readings, or no echo. If itis determined the gain needs to be changed, usethe following procedures:

NOTE: The gain adjustment is set at the factoryusing precision instruments and should not bechanged unless absolutely necessary.

1. Remove six screws from the back cover andremove the cover.

2. Locate gain adjustment (Illustration 28) on thetop printed circuit board.

3. Before turning this adjustment, check and see ifthe position is marked. If not marked, place amark on the small plastic case. This is thefactory setting of the gain adjustment which wasset using instruments. Marking this position willallow you to return it to its original setting if youhave trouble with the operation of the IndicatorIII during this procedure.

4. Make sure the beeper is ON, which is selectedas ON or OFF in the Settings menu.

5. To adjust the gain, use a small flatheadscrewdriver to turn the gain adjustment whilemeasuring 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 nomeasurement taken).

b. Turning the adjustment counterclockwise (left)increases the gain.

NOTE: If the gain is increased too much, thebeeper will not turn OFF when the probe isremoved from the component being measured.

c. The correct setting is when the gain control isset to the most counterclockwise position thatwill allow readings to be taken easily, and thebeeping stops when the probe is removed. Itmay take some trial and error and tryingvarious component measurements before thebest setting is obtained.

6. Once this setting is obtained, replace the rearcover.

TroubleshootingIf the Indicator III does not operate properly, firstcheck the Battery Level Monitor to see if thebatteries have sufficient power remaining. If not,and NiCad batteries are installed, then recharge orreplace them with new alkaline batteries.

As the rechargeable batteries age, they will provideless operating time for the Indicator III. When theoperating time between charging is unacceptable,the batteries should be replaced with new NiCadbatteries.

NOTE: The longest life will be obtained bycharging the batteries only after the display isflashing, indicating the batteries are fully or nearbeing discharged.

If the Battery Level Monitor shows the batterieshave sufficient power remaining and the Indicator III still will not turn ON, it must be sent infor repair. Refer to the Service section in thismanual.

If the display comes on but the Indicator III will nottake measurements, the problem may be in theprobe.

If you have another probe that is known to begood, try it and see if it works. If not, use thefollowing 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 soundemitted by the probe.

5. Remove the probe cable connector from theIndicator III and turn it around in the PROBEconnector so the tab is at the rear of theIndicator III. The cable connector will not fitcompletely against the connector panel, but willstill make contact. Again, with the Indicator IIION, you should hear the sound emitted by theprobe. If you do not hear the sound both times,the probe has failed and must be replaced.

6. Sometimes the crosstalk barrier (between thetwo halves on the face of the probe) becomesworn or saturated with couplant. This can resultin bad readings or readings while not measuringany material. If this problem occurs, tryadjusting the gain of the Indicator III. If this failsto correct the problem, replace the probe.

33

34

SOFTWARE VERSION3.1

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/YYYYDATE 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 PUSHPUSH AND HOLD BOTH KEYSAT SAME TIME FOR 3 SECONDS

KEYS

MACHineDISPLAYS

ARROWKEYS

LOC/MACHKEY

LOCationDISPLAYS

TYPICALDISPLAYSVALUE

KEY

ARROWKEYS

REDSHIFT "D" KEY

"9" KEY

SAVEKEY

VALUEKEY

ARROWKEYS

TO PACKING CONDDISPLAY

CLRMACH

1 MILES – – – – – –

1 MILES / WEEK – – – –

0730-30

Undercarriage Measurement Display MapNOTE: Settings menu in default states.

35

VALUEKEY

ARROWKEYS

1 PACKING COND 2 MODERATE

1 R IDLER DEPTH 0.00 0.00IN

1 BUSHING TOOL2 CALIPER

1 BUSHING TOOL3 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 INT0.00 0.00IN

1 L BUSHING EXT0.00 0.00IN

1 BUSHING TOOL1 ULTRASONIC

1 L SHOE 0.00 0.00IN

1 SHOE TOOL1 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 TOOL1 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 CONDDISPLAY

TO L ROLLER 7DISPLAY

0730-31

LOCation Display MapNOTE: Settings menu in default states and units are inches.

36

ARROW KEYS ARROW KEYS

BACK TO STARTMODEL DISPLAY

ARROW KEYS

FROM L ROLLER 6DISPLAY

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 TOOL1 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 (cont’d)

9U-7981 Couplant MaterialSafety Data Sheet(To comply with 29 CFR 1910, 1200) Effective Date: 2/98N/A = not applicable or not available

Section 1 — Product IdentificationProduct 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 . . . . . . . . . . . . >220°F pH: 7.35 to 7.9

Freezing Point . . <20°F Acoustic Imp.: 1.726 x 106

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 HazardData

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 DataStability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stable

Conditions to Avoid . . . . . . . . . . . . . . . . . . . . . none

Incompatibility (Materials to Avoid) . . . none known

Hazardous Polymerization . . . . . . . . . will not occur

Hazardous Decomposition or Byproducts . . . noneknown

Section 6 — Health Hazard and First AidData

Routes of Entry1:

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 HandlingInformation

Precaution to be taken in handling and storage:

Store between 20°F and 120°F. Spills are slipperyand should be cleaned up immediately.

Steps to be taken in case material is released orspilled:

Pick up excess for disposal. Clean with water.

Waste disposal method:

Dispose of in accordance with federal, state, andlocal regulations.

Section 8 — Control MeasuresRespiratory Protection . . . . . . . . . . . . . not required

Ventilation . . . . . . . . . . . . . . . . . . . . . . not required

Protective Gloves . . On individuals demonstratingsensitivity to 9U-7981 Couplant.

Eye Protection . . . . . . . . . . . . . . . . . As required by working conditions

Other Protective Equipment . . . . . . . . not required

19U-7981 Ultrasonic Couplant contains only foodgrade and cosmetic grade ingredients.

37

ServiceIf the Ultrasonic Wear Indicator III does not operatecorrectly, recharge or replace the internal NiCadbatteries with new ones and check the operation.If it still does not operate, refer to theTroubleshooting section in this manual. If theIndicator III is found to be faulty, contact DealerService Tools for information on how to obtain theneeded repair service.

Dealer Service Tools provides the instrument's userwith a warranty of one year from purchase date. Ifthe reason for failure is determined to be abuse,the warranty is declared void. Any out-of-warrantyrepairs will be charged to the owner.

For any product support questions with yourinstrument, contact Dealer Service Tools at:

501 S. W. JeffersonPeoria, IL U.S.A. 61630-2125U.S.A.: 1-800-542-8665Illinois: 1-800-541-8665Canada: 1-800-523-8665World: 1-309-675-6277Fax: 1-309-494-1355dealerservicetool_hotline@cat.com

If the instrument, or any part of it needs repair, thencontact and send it to:ATS (Advanced Technology Services)8201 North University AvenuePeoria, Illinois USA 61615Phone: (800) 328-7287 (Inside USA)

(309) 693-4000Fax: (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 CaterpillarAll Rights Reserved

NEHS0730-02Printed in U.S.A.