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

NEHS0730-03 11 September 2013

Tool Operating Manual Charging the Internal NiCad (rechargeable) Batteries ........................................................10 Procedure.....................................................10 Replacing The Internal Rechargeable Batteries ..................................................... 11 Connecting To DC power...................................12 Care and Cleaning Of 168-7721Indicator III...................................................................13 Remove the 9U-7981Couplant Residue ............13 Cleaning the Case and Front Panel Key Pad ............................................................13 Care of Connectors .......................................13 Operating Instructions for 168-7721Indicator III ......................................................................13 Turn the Indicator III ON ....................................13 Calibrating the Indicator III Probe .......................14 Undercarriage Measurement Procedure .............15 Clearing The Memory........................................15 Using LOC(ation) Mode of Operation..................16 List of Undercarriage Storage LOC(ation) Displays......................................................16 Entering Information into the Indicator III.............17 Changing Displays with Words ..........................18 Measuring Track Sag ........................................18 Taking Ultrasonic Measurements .......................18 Saving Measured Values in Memory...................19 Tool Displays....................................................19 Measurement Operating Tips.............................19 Undercarriage Measurement Techniques...............20 Track Links ......................................................20 Track Shoes.....................................................20 Track Bushing ..................................................20 Idler.................................................................21 Carrier Roller....................................................21 Three Piece Rims..........................................21 Track Roller......................................................22 Competitive Parts .............................................22 Measuring the Thickness of Parts Other than Undercarriage.................................................22 Transferring the Memory Values To or From a Computer ..........................................................22 Settings Menu .....................................................24 Resolution........................................................27 Turnoff.............................................................27 Velocity............................................................27 Serial...............................................................27 Beeper ............................................................27 Language ........................................................27

i04778305

168-7720 Ultrasonic Wear Indicator III Group SMCS Code: 0374; 0599; 0729; 0787

Caterpillar Products All

Table of Contents Introduction ...........................................................2 Literature Information .............................................2 Safety Section....................................................2 General Information Section ................................3 Operation Section...............................................3 Maintenance Section ..........................................3 Service Parts Section..........................................3 Safety Icon Nomenclature ...................................3 Personal Protection/Important Information....................................................3 Prohibited Action .............................................3 Hazard Avoidance...........................................3 General Information ...............................................3 Introduction ........................................................3 Additional Contact Information .............................4 Other Uses for The Indicator III ............................4 Benefits Ultrasonic Wear Indicator III....................4 Features of the Indicator III...............................4 General Measurement Benefits............................4 Undercarriage Measurement Benefits ..................5 168-7720Ultrasonic Wear Indicator III Group..................................................................5 Storage Of Conventional Tools ............................5 Optional Items ....................................................6 168-7720Ultrasonic Wear Indicator III Group Specifications .........................6 168-7722Ultrasonic Probe Specifications ...................................................7 156-1077Power Inverter Specifications ...................................................7 Connections to the 168-7721Indicator III.............8 168-7721Indicator III Description.......................................................8 Abbreviations and Descriptions Used on Front Panel and Key Pad ...............................8

1

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

Distance ..........................................................27 Date ................................................................27 Ultrasonic Velocity Adjustment ..............................27 Checking the Ultrasonic Velocity ........................28 Changing the Ultrasonic Velocity........................28 Battery Level Monitor ........................................29 Low Battery Indication.......................................29 Return to Last Menu Screen ..............................29 Factory Reset...................................................29 Viewing the Software Version Screen .................29 Checking the Operation of the Indicator III...................................................................30 Alternate Method...........................................30 Adjusting the Display Contrast ...........................30 Adjusting the Gain ............................................30 Troubleshooting ...................................................31 Undercarriage Measurement Display Map..............31 Location Display Map ...........................................33 9U-7981Couplant Material Safety Data Sheet ................................................................36 Service ...............................................................37

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below. A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

Introduction Important Safety Information

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Illustration 1

Literature Information

g02139237

Think Safety

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

European Union Compliant, CE Marked Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety Section The Safety section lists basic safety precautions.

2

Prohibited Action

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

No smoking –

General Information Section Hazard Avoidance

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Crushing hazard (foot) –

Crushing hazard (hand) –

Operation Section The Operation section is a reference for the new operator and a refresher for the experienced operator.

Pinch point –

Photographs and illustrations guide the operator through correct procedures for using the tool group. Fire hazard – Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Electrical Shock - Hazard –

Maintenance Section Fire hazard –

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

General Information

The Service Parts section is a reference for parts identification and available part numbers.

Introduction

Safety Icon Nomenclature Personal Protection/Important Information

Illustration 3

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168-7721 Ultrasonic Wear Indicator III

The 168-7720 Ultrasonic Wear Indicator III Group provides a new, fast, and accurate method of measuring track-type machine undercarriage wear.

Illustration 2

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.

g02166423

Personal Protection/Important Information

3

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.

Features of the Indicator III

The Ultrasonic Wear Indicator III measures the part thickness by sensing high frequency sound waves through the material to be measured. When the sound reaches the opposite side of the part, sound is reflected back and received by the probe. The time required for the sound to travel through the part and be received determines the thickness of the part. The microprocessor in the Indicator III converts the time into a thickness value and displays value.

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

• New design uses state-of-the-art surface mount electronics for high reliability. • For battery access - loosen the two battery cover screws on the back of the Indicator III.

• 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.

When taking measurements. The 9U-7891 Couplant must be applied to the sensing end of the probe before measuring. This allows the sound to be transferred into the part being measured. For convenience, the couplant container attaches to the side of the Indicator III.

•

Additional Contact Information

168-7720 Ultrasonic Wear 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.

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at:

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

USA 1-800-542-8665, Option 1 International 1-309-578-7372

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

Other Uses for The Indicator III

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

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

General Measurement Benefits • Higher accuracy measurements. Digital display of thickness is accurate to 0.10 mm (0.004 inch) for low-resolution mode, and 0.01 mm (0.0004 inch) for high-resolution mode.

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

• Time savings in measuring undercarriage due to reduced cleaning and measurement storage. • Easy to use. Thickness reading will always appear on the display when the probe is used, regardless of mode of operation. • Calibrated for undercarriage steel, but velocity can be adjusted to measure other materials such as aluminum, plastic, and glass. • Reads thickness of parts where opposite side is not accessible, such as a bulldozer blade, bucket base ledge, or scraper bowl thickness. • No writing. Stores readings in memory, then transfers to a computer for printing.

4

Undercarriage Measurement Benefits

(Table 1, contd)

• 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.

(7)

-

Paper Towels (16 sheets from 9U-6000 Paper Towel Case)

-

NEHS2835

168-7720 Group Label (located in lid of carrying case)

-

-

-

NEHS0730

Four 1-9/16 inch protective caps for RS232 connector Ultrasonic Wear Indicator III Group Tool Operating Manual

Storage Of Conventional Tools

• 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.

168-7720Ultrasonic Wear Indicator III Group

Illustration 5

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Storage For Conventional CTS Tools In 6V-7145 Carrying Case Refer To Table 2 For Item Identification Table 2 Storage Locations

Illustration 4

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168-7721 Ultrasonic Wear Indicator III

Item

Part No.

Description

(1)

PEKP9400

(2)

5P-3277

Tape Measure: 3 m (9.8 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

Custom Track Service Handbook: Fits under Indicator III

Refer To Table 1 for Item Identification Table 1 168-7721 Ultrasonic Wear Indicator III Item

Part No.

Description

(1)

168-7721

Ultrasonic Wear Indicator III (Calibration Certificate not shown)

(5)

5P-8617

Sprocket Gauge: For D7, D8, and D9 Track-Type Tractors

(2)

168-7722

Ultrasonic Probe (Declaration of Conformity not shown)

(6)

6V-9410

Depth Gauge: For measuring idlers

-

5P-3920

(3)

9U-7981

Couplant

Steel Rule: 300 mm (11.8 inch), store on top of 9U-6000 Paper Towels

(4)

6V-7145

Carrying Case

(5)

4C-4772

Foam Insert

(6)

4C-3024

Battery Charger (110/220 VAC, 50/60 Hz)

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.

(continued)

5

Note: The part numbers for other conventional undercarriage tools can be found in the CTS Handbook.

(Table 3, contd)

Optional Items

-

-

Additional Service Replacement Part (not shown)

-

4C-5490

Couplant Holder: The service replacement for the holder that stores the 9U-7981 Couplant container.

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 6

g02901761

Optional Items For 168-7721 Ultrasonic Wear Indicator III Table 3 Optional Items Item

Part No.

Description

(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

Illustration 7

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 12 VDC and includes battery cables and a cigarette lighter.

(7)

9U-6175

Soft Protective Case: For protecting the 168-7721 during use.

-

-

g02901776

168-7721 Ultrasonic Wear Indicator III With 168-7722 Probe Installed in 9U-6175 Soft Protective Case

168-7720Ultrasonic Wear Indicator III Group Specifications Power Supplied By: ........ 5 NiCad (Nickel Cadmium), rechargeable batteries (size AA) or non-rechargeable 1U-9533 Alkaline Batteries. Note: The five AA batteries are accessed by removing the Indicator III back cover. See the Section “Replacing The Internal Rechargeable Batteries” for the procedure. NOTICE DO NOT attempt to recharge alkaline batteries using the 4C-3024 Battery Charger.

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.

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.

(continued)

6

Weight:

Approximate Battery Life (with Indicator III backlight OFF and beeper ON)

168-7720 Group ....................................3 kg (6.6 lb)

NiCad Rechargeable ....................................19 Hours

168-7721 Indicator III ......................... 0.9 kg (2.0 lb)

Alkaline Non-rechargeable ...........................47 Hours

168-7722 Probe ..........................0.113 kg (0.249 lb)

Approximate Battery Life (with Indicator III backlight and beeper ON)

168-7722Ultrasonic Probe Specifications

NiCad Rechargeable ....................................14 Hours

Probe Type .................Dual Element 7.5 MHz special application

Alkaline Non-rechargeable ...........................34 Hours

Probe Size:

Indicator III shuts down .....................................5.12 V

Measuring Surface Diameter ............11 mm (0.4 inch)

Power Line Operation:

Length...............................................42 mm (1.7 inch)

4C-3024 Battery Charger .......110 VAC or 220 VAC, 50/60 Hz

Diameter........................................... 19 mm (0.8 inch)

Measurement Range (Steel) .............. 1.27 to 254 mm (0.050 to 10.0 inch)

Allowable Surface Temperature ............−18° to 150°C (−0.4° to 270.0°F)

Measuring Resolution:

Cable Length .............................. 1524 mm (60.0 inch)

Low Resolution (default) ±........... 0.1 mm (0.004 inch)

Includes Certificate of Conformity

High Resolution ± ....................0.01 mm (0.0004 inch)

156-1077Power Inverter Specifications

Measurement Accuracy:

Input Voltage Range ........................10.5 to 14.5 VDC

Low Resolution (default) ±........... 0.1 mm (0.004 inch)

Input Voltage Protection .... Automatically shuts down if voltage exceeds 15 VDC (the inverter will be damaged if connected to a 24 VDC battery)

High Resolution ± ....................0.076 mm (0.003 inch) Operating Temperature: ..........................−18° to 60°C (−0.4° to 108.0°F)

Low Battery Indicator ....Audible alarm sounds if input voltage drops to 10.6 VDC

Storage Temperature: Output ........................................................... 115 VAC Without Batteries Installed.......................−40° to 60°C (−40.0° to 108.0F)

Operating Temperature Range:..............10° to 26.7°C (50.0° to 48.06°F)

With Alkaline Batteries Installed (less than 6 months) ....................................−40° to 50°C (−40.0° to 90.0°F)

Memory Size:

Over Temperature Protection: ..........When the power inverters internal heat sinks reach 65.5°C (150 °F), the inverter will automatically shut down. The inverter may be “restarted” by first disconnecting the inverter and allowing to cool for 15 minutes before reconnecting.

Flash Memory ........................................32,768 Bytes

No Load Current Draw ....................... Less than 0.2 A

Random Access Memory (RAM) .............. 1024 Bytes

Output Receptacle ................................. Dual 3-prong

Electrically Erasable Memory ................49,830 Bytes

Fuse ...........................................35 Amp (spade type)

RS232 Specifications ............1200, 9600 (default), or 19,200 Baud rate

Weight ................................................. 1.6 kg (3.53 lb)

LCD Backlit Display ..................2 Line x 16 Character

Dimensions....................................155 x 127 x 58 mm (6.1 x 5.0 x 2.3 inch)

External Dimensions:

Maximum Continuous power ............................300 W

With NiCad Batteries Installed (less than 6 months) ....................................−20° to 45°C (−4.00° to 81.0°F)

6V-7145 Carrying Case ...........432 x 390 x 114 mm (17.0 x 15.4 x 4.5 inch)

Surge Capability (Peak Power) ........................ 600 W Overload Protection ........ Inverter automatically shuts down if continuous power is greater than 300 W

168-7721 Indicator III .................190 x 168 x 40 mm (7.5 x 6.6 x 1.6 inch)

7

Connections to the 168-7721Indicator III

(Table 4, contd) (6)

Probe

(7)

-

Connector Used to install the 168-7722 or 4C-5485 Ultrasonic Probe Earphone Connector (mono) Used to connect earphone to hear beepers sound in noisy environments. The beeper can only be heard when an earphone jack is installed in the earphone connector.

168-7721Indicator III Description

Illustration 8

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Connectors For 168-7721 Indicator III Refer to Table 4 for item identification. Table 4 Connectors For 168-7721 Indicator III Item

Part No.

Description

(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 the Section “Calibrating the Indicator III Probe” in this manual.

(4)

RS232

Connector (shown without 1 9/16 inch protective cap installed) Used to connect 4C-5488 Cable Assembly RS232 (PC AT) or 4C-5489 Cable Assembly RS232 (PC XT) or 4C-5897 Cable Assembly RS232 (Modem Cable) These cables can be used to transfer stored undercarriage data from the 168-7721 to a personal computer or printer. Refer to the Section “Optional Items” in this manual, for each cables-specific function and software program requirements.

(5)

-

Illustration 9

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168-7721 Indicator III Front Panel And Key Pad

Abbreviations and Descriptions Used on Front Panel and Key Pad 1. MACH: Machine, referred to as MACH(ine) in this manual. 2. 6.3 mm (0.25 inch):

Charger Connector Used to connect the Battery Charger when recharging the rechargeable Batteries (NiCad). Also used to power the 168-7721 with the 4C-3024 Battery Charger. The plug of the 4C-3024 can be plugged into the 156-1077 Power Inverter to provide 12 VDC power for powering the indicator.

Describes the metal calibration disk thickness measured in millimeters and inches during probe calibration (metal calibration disk is located on top panel). 3. RS232:

(continued)

8

Identifies connector located on top panel which provides the RS232 signal connection, for the optional cables, for transferring data to a personal computer. Refer to the Section “Optional Items” in this manual for each cables-specific function, software requirements, and use with the 168-7721 Indicator III.

12.MM/IN: Changes the display values from MM (millimeter) to IN (inch) and will work only when a value is on the display. Also used to show ultrasonic velocity. Refer to the Section “Velocity” in this manual. 13.PROBE CAL:

4. CHARGE:

Calibrates the ultrasonic probe so the Indicator III will read accurately.

Identifies the connector, located on top panel, for the 4C-3024 Battery Charger.

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.

5. PROBE: Identifies the connector, located on the top panel, for the 168-7722 or 4C-5485 Ultrasonic Probe.

If the MEASURED VALUE display is not 6.3 mm (0.25 inch) while in the Low Resolution mode, press PROBE CAL while holding the probe on the disk and display should read correctly.

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

If the MEASURED VALUE display is not in the range of 6.25 to 6.32 mm (0.246 to 0.249 inch) while in the High Resolution mode, press PROBE CAL while holding the probe on the disk and display should read correctly.

Description of Displays and Keys 7. MACH(ine) DISPLAY: Identifies the machine number (from 1 to 64) corresponding to the information on the display. When data is saved, data can be located later by going to this machine number.

Refer to the Section “Calibrating the Indicator III Probe” and the Section “Ultrasonic Velocity Adjustment” in this manual. 14.ON/OFF:

8. LOCATION Display:

Turns Indicator III ON or OFF. Shows the undercarriage storage LOC(ation) display selected by the up or down arrow keys and shows the machine model when in the MACH(ine) mode of operation. The display, in Figure 9, is in the LOC(ation) mode.

Indicator III will automatically turn OFF after 5 minutes if not in use. This function can be disabled in the Settings Menu. Refer to the Section “Settings Menu” in this manual. 15.CLR/CLR MACH:

9. MEASURED VALUE:

This key will provide one of two functions:

Displays the thickness value being measured or the value of the last measurement taken. MM or IN will appear to the right of the value displayed, when measuring, to show that the probe is properly coupled to the material.

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.

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.

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.

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

16.LOC/MACH:

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.

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.

SET:

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

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.

9

In the LOC(ation) mode, the LOCATION display does not show the letters MACH, but instead describes the inspection information or undercarriage measurement location.

If a word appears for MEMORY VALUE:

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.

RIGHT ARROW:

Press VALUE to select other words available. Press SAVE to leave the display as selected

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.

17.LEFT ARROW, A or B: This key will provide one of two functions:

21.SHIFT (blue):

In the LOC(ation) mode, the flashing cursor is moved one position to the left for each key press.

Used to enter any blue character from the key pad.

When preceded by pressing either the red or blue SHIFT key, the corresponding colored character is entered on the display.

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

18.UP ARROW / BACKLIGHT:

Note: The SHIFT keys are to be pressed and released before pressing the desired character key.

This key will provide one of two functions:

23.Alphanumeric keys:

UP ARROW:

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.

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.

Charging the Internal NiCad (rechargeable) Batteries

If LOCATION display does not read MACH, press the up arrow key to advance to the next measurement location. This is the LOC(ation) mode of operation. Hold the up arrow key to scroll in the MACH(ine) or LOC(ation) Display Mode. BACKLIGHT: Press and release the blue SHIFT key, then press this key to turn ON the display backlight. Perform the same keystrokes to turn the backlight OFF. Note: When Ultrasonic Wear Indicator III is in Manual Turn off mode (selectable in the settings menu): If backlight is ON, no key has been pressed, and probe not coupled for 5 minutes, then the backlight will turn OFF. The backlight will automatically turn ON when a key is pressed or probe is coupled.

Illustration 10

g02901896

Rear View Of 4C-3024 Battery Charger

19.DOWN ARROW:

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.

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.

The batteries must be charged before using the 168-7720 Ultrasonic Wear Indicator III Group. Procedure

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:

1. Move switch (1) on the rear of 4C-3024 Battery Charger(2) to the correct AC line voltage, either 120 V or 230 V, depending on use.

Enter the desired characters.

2. Connect charger connector (3) into the CHARGE connector located on the top of the Indicator III.

Press SAVE to leave the display as selected.

10

3. Plug power supply end (4) into an AC outlet. Note: For operation outside the USA, an AC power plug adapter may be required. 4. Turn the Indicator III ON to check if the batteries are being charged. It may be necessary to wait a few minutes until the batteries are sufficiently charged to operate the Indicator III. 5. When first turned ON, the display may flash, indicating low voltage. The flashing should stop after a few minutes as the batteries are charged. 6. Turn the Indicator III OFF and leave the charger ON for 10 to 14 hours.

Illustration 11

g02901899

Note: The Indicator III will not be damaged if the charger is left on for longer time periods.

Back View Of 168-7721 Ultrasonic Wear Indicator III

Note: For maximum battery life, recharge only after the display flashes or goes blank, indicating the batteries are near or fully discharged.

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

Replacing The Internal Rechargeable Batteries The 168-7721 Ultrasonic Wear Indicator III is supplied with five NiCad (Nickel Cadmium), rechargeable batteries (size AA). The batteries can be replaced with new 1U-7445 Batteries when the batteries no longer give sufficient operating time. The batteries can be replaced with 1U-9533 Alkaline Batteries (non-rechargeable). Note: The internal batteries can be removed indefinitely and the internal memory values will not be affected.

Illustration 12

g02901900

Indicator III With Battery Cover Removed

NOTICE DO NOT attempt to recharge alkaline batteries using the 4C-3024 Battery Charger.

2. Remove battery cover (2). 3. Remove all batteries (3) and replace with new batteries.

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 13

g02901905

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

11

Connecting To DC power

Illustration 14

g02901907

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

4. To install new batteries: The (+) terminal of the battery must be placed on the battery contact with the (+) symbol (4) (in the recessed area of the battery compartment, as shown in Figures 13 and 14 ). Illustration 16

The easiest way to install the batteries is to place the (-) terminal of one battery against one of the negative battery contacts (does not have (+) sign) inside of the battery compartment (5). Compress the negative battery contact as much as possible (see Figure 15 ) and then install the plus terminal (+) of the battery into the battery compartment.

g02901921

156-1077 Power Inverter

(1) Power Inverter (2) Cigarette Lighter Adapter (3) Manual (4) Battery Power Clips Attached To Cable (5) Installed Fuse (6) Extra Fuses (7) Two Outlets That Accept The Power Cables Plug Supplied With The Emission Analyzer (8) ON/OFF Switch

1. The optional 156-1077 Power Inverter (12 VDC) may be used to connect the 168-7721 Indicator to an external DC power source. 2. Plug the power plug of the 4C-3024 Battery Charger into one of the two outlets on the 156-1077 Power Inverter. Refer to Figures 10 and 16. 3. When using the battery from a machine or engine as the power source, power the emission analyzer by connecting the power cable clip with the black colored handle to the machine or engines frame or to the battery negative terminal. Connect the power cable clip with the red colored handle to the battery positive terminal.

Illustration 15

NOTICE The 156-1077 Power Inverter requires a 12 VDC input. Make sure not to exceed this specification or the power inverter fuse may blow resulting in possible damage to the power inverter. Also, reverse polarity could damage the power inverter, but will most likely blow the 35 A fuse. Refer to item (5) Figure 11.

g02901918

Installing Battery Cover

4. The 168-7721 Indicator can also be powered by a vehicles 12 VDC cigarette lighter. Remove the cable with the power clips from the power inverter. The power inverter can now be plugged into a cigarette lighter on a vehicle. Refer to Figure 16.

(5) Battery (-) Negative Terminal (6) Battery (+) Positive Terminal

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

12

Care and Cleaning Of 168-7721Indicator III

Turn the Indicator III ON

The 168-7721 Ultrasonic Wear Indicator III is a durable hand held instrument. Since it will be used outdoors in a wide range of conditions, care must be taken to protect keep it clean.

1. Press and release the ON/OFF key.

The case is water resistant, but not waterproof, and the instrument can be damaged if water is allowed to enter the case. If moisture does enter the case, the Indicator III should be allowed to dry out. Remove the rear cover and battery cover and allow to dry completely in a warm, dry area.

Illustration 17

g02901927

Copyright Display

Keep the Indicator III stored in the carrying case when not in use.

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.

Remove the 9U-7981Couplant Residue When taking measurements, all excess 9U-7981 Couplant residue should be removed from the probe, Indicator III, and case with paper towels before the residue dries. The couplant is water soluble and a damp cloth can be used to remove any residue that has dried. Care must be taken so no water enters the Indicator III case.

Illustration 18

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Cleaning the Case and Front Panel Key Pad

MACH Display (Memory Clear)

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.

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.

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.

Illustration 19

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MACH Display (Last Machine Used)

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

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.

Operating Instructions for 168-7721Indicator III

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.

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

13

Calibrating the Indicator III Probe Before taking measurements, the accuracy of the Indicator III and probe must be checked and the Indicator III and probe recalibrated, if needed. This procedure should be performed at the start of each day and anytime the accuracy is in question to ensure the readings taken will be accurate. Once the Indicator III and probe are calibrated with this procedure, it will ONLY be accurate for measuring undercarriage steel or steel of a similar type. If other materials are measured, the velocity must be changed and a different PROBE CAL value used. Refer to the Section “Ultrasonic Velocity Adjustment” in this manual.

Illustration 21

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Ultrasonic Wear Indicator III And Probe Being Calibrated

A metal calibration disk, Figure 21, is used to check the accuracy and calibrate the Indicator III and probe. 1. Place a small amount of 9U-7981 Couplant on the sensing end of the probe. See Figure 20. 2. Press the probe against the metal calibration disk on the top of the Indicator III. See Figure 21. 3. A number will appear at the MEASURED VALUE display. If the probe is properly coupled to the disk, the MM or IN indicator will also be displayed. Also, a beeping sound will be heard (if not turned OFF using the Settings menu) to indicate good coupling. Illustration 20

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Applying Couplant To Ultrasonic Probe

Illustration 22

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Probe On Calibration Disk NOT In Calibration

Note: The thickness value and the units (0.25 IN) flash while the probe is coupled and the beeping sound occurs at the same rate. 4. The display value should be 6.3 mm (0.25 inch) when in the Low Resolution Mode. If not correct as shown in Step 3, follow the instructions in Step 6.

14

Undercarriage Measurement Procedure Note: When using this procedure, refer to the Section “Undercarriage Measurement Display Map” in this manual, for additional information on the sequence of the displays.

Illustration 23

1. The Indicator III MUST be calibrated before any measurements are taken. Refer to the Section “Calibrating the Indicator III Probe”.

g02901964

Probe Removed From Calibration Disk

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

5. If the calibration is correct, as shown in Step 4, proceed to the Section “Undercarriage Measurement Procedure”.

Clearing The Memory

6. To calibrate the Indicator III and probe, press the PROBE CAL key. The display should now show (PROBE).

Illustration 24

1. If a (CLEAR) machine cannot be located, any one or all machines can be cleared by first pressing and releasing the red SHIFT key and then pressing CLR MACH key.

g02901967

PROBE CAL Key Pressed

7. Place a small amount of the 9U-7981 Couplant on the sensing end of the probe. Press the probe to the metal calibration disk. See Figure 21.

Illustration 25

Illustration 26

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2. Press the Value key to clear one machine (Machine 2 in this example).

g02901970 Illustration 27

Calibration Complete

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Display While One Machine Is Being Cleared

8. The MEASURED VALUE, shown in Step 7, should now be correct. If not, repeat this procedure until correct.

3. The message shown above will appear on the display for a short time. The (CLEAR) message indicates the memory has been cleared and is ready for a new data.

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

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.

Note: An alternate method of calibration is to press the PROBE CAL key while holding the probe on the disk. If the Indicator III still will not calibrate correctly, check for the proper velocity setting for undercarriage steel. Refer to the Section “Ultrasonic Velocity Adjustment” in this manual.

15

(Table 5, contd)

Illustration 28

9

IMPACT 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

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

27

L CAR. ROLL 2


28

L CAR. ROLL 3


29

CAR. ROLL TOOL

Measuring tool used on carrier rollers. SET DIGIT: ULTRASONIC, CALIPER

30

L ROLLER 1

Left track roller number 1

31

L ROLLER 2


g02901976

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 operation. To change to the LOC(ation) mode from the MACH (ine) mode, press the LOC/MACH key. This key always changes the display to the other mode of operation. If the word MACH is not on the display, the Indicator III is in the LOC(ation) mode. Once in the LOC(ation) mode, the 71 different undercarriage storage locations shown in Table 5, “List of Undercarriage Storage LOC(ation) Displays” are available for use. These storage locations can be accessed with the up and down arrow keys. Refer to the Section “Undercarriage Measurement Display Map” in this manual for additional information on how to change between the various displays. List of Undercarriage Storage LOC(ation) Displays

Front idler ultrasonic measurement use SET DIGIT

Table 5 Loc. 1

Display MODEL

Notes The machine model number

SERIAL NUMBER

The machine serial number

DATE MM/DD/ YYYY DATE DD/MM/ YYYY

The date by month, day, year The date by day, month, year

4

HOURS

The service hour meter reading on the machine

32

L ROLLER 3


5

HRS/WEEK

The number of hours the machine has worked per week

33

L ROLLER 4


34

L ROLLER 5


6

MILES KM

The reading on the machines odometer in miles or kilometers

35

L ROLLER 6


7

MILES/WEEK KM/WEEK

The distance the machine has traveled per week

36

L ROLLER 7


37

L ROLLER 8


8

JOB SITE

The location of the machine

38

L ROLLER 9


39

L ROLLER 10


2 3

(continued) (continued)

16

(Table 5, contd) 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

48

F IDLER DEPTH Front idler depth gauge measurement - use SET DIGIT

49

F IDLER SONIC

50

R IDLER DEPTH Rear idler depth gauge measurement - use SET DIGIT

Illustration 29

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MODEL Display With Empty MODEL Number

Right shoe measurement

Front idler ultrasonic measurement

51

R IDLER SONIC

Rear idler ultrasonic measurement

52

A CAR. ROLL 1

Right carrier roller number 1

53

A CAR. ROLL 2


54

A CAR. ROLL 3


55

A ROLLER 1

Right track roller number 1

56

A ROLLER 2


57

A ROLLER 3


58

A ROLLER 4


59

A ROLLER 5


60

A ROLLER 6


61

A ROLLER 7


62

A ROLLER 8


63

A ROLLER 9


64

A ROLLER 10


65

R SPROCKET

Right sprocket - use SET DIGIT

66

NOTES LINE 1

16 characters - use SET DIGIT

67

NOTES LINE 2


68

NOTES LINE 3


69

NOTES LINE 4


70

SPARE # 1

For extra measurement

71

SPARE # 2

For extra measurement

Illustration 30

g02902017

MODEL Display Containing MODEL Number

The first storage location is MODEL. This display is shown above in the way it appears with and without a model number in memory. The machine model number can be entered where the dotted line is or a number already shown can be changed. This display will always be the first display shown when switching from the MACH(ine) or LOC(ation) mode of operation.

Entering Information into the Indicator III If the memory contains a MODEL number, the model number will always be shown on the display. If memory does not contain a MODEL number, dashed lines will show where the model number should be entered. To enter the MODEL, press the VALUE key and the first number digit location will become a blinking box. Whenever a blinking box is on the display, numbers or alphabetical characters may be entered directly using the keys on the front panel. To enter the red characters, the red SHIFT key must be pressed and released before the character key is pressed. To enter a blue character, the blue SHIFT key must be pressed and released before the character key is pressed. Continue this procedure until the entire MODEL number is on the display. When finished, press the SAVE key and the MODEL number will be stored in memory.

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.

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

17

To enter the serial (product identification) number into the SERIAL NUMBER display, follow the same procedure as used in the Section “Using LOC(ation) Mode of Operation”.

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.

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.

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

The same procedure will be used for entering:

Measuring Track Sag

• DATE

The first display for a measurement is L TRACK SAG (left track sag). This measurement cannot be taken with the Indicator III.The measurement must be taken according to the instructions in the CTS handbook with a tape measure and manually entered into the III memory.

• HOURS • HRS. PER WEEK • MILES or KM

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

• MILES PER WEEK or KM PER WEEK • JOB SITE, and

2. The first digit of the MEMORY VALUE will flash, allowing the measurement to be entered. Refer to the Section “Entering Information into the Indicator III”.

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.

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.

Illustration 31

Note: Refer to the Section “Undercarriage Measurement Techniques”, in this manual, for details on how to measure each undercarriage component.

g02902042

Example Of IMPACT With Alternate Word MODERATE

1. To take a measurement, place a small amount of 9U-7981 Couplant on the sensing end of the probe and press firmly and squarely against the wear surface. 2. The measurement will appear on the display above MEASURED VALUE.

Illustration 32

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.

g02902043

Example Of IMPACT With Alternate Word HIGH

Note: The thickness value and its units (4.92 IN) flash while the probe is coupled and the beeping sound occurs at the same rate. 4. When you are satisfied a good value is on the display, remove the probe and that value will remain in the MEASURED VALUE display. Illustration 33

Note: Measurements can only be taken in the MACH (ine) Display Mode or in LOC(ation) Display Modes screen that accepts ultrasonic measurements.

g02902044

Example Of IMPACT With Alternate word LOW

18

Saving Measured Values in Memory

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.

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.

Continue through the LOCATION displays until all of the undercarriage measurements have been taken and recorded.

To make sure that the number was recorded correctly, press the down arrow key to go back to the previous LOCATION. The value measured will show on the MEMORY VALUE display.

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

Note: While taking an ultrasonic measurement, once satisfied of a good measurement, press the “SAVE” key before removing the probe.

When finished with the measurements, advance to the next machine by pressing “LOC/MACH” and the up arrow key.

Tool Displays

Measurement Operating Tips

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:

The following operating tips will make it easier to take measurements with the Indicator III.

Illustration 34

1. The sequence of the undercarriage storage locations were selected to transfer into the Custom Track Service personal computer program. Until you have this program, it may save time to enter and save only the serial number and measurements in the indicator III. Then manually record the data for locations 2 through 13 directly on the CTS Form. Refer to the Section “General Information”. After taking measurements, scroll through the stored measurements while manually recording them on the CTS form. 2. When using the arrow keys, press and release the keys to change the display slowly, or hold the key down to scroll rapidly.

g02902121

Example of BUSHING TOOL with type of tool used: ULTRASONIC

Illustration 35

3. For users preferring not to use the memory feature, ultrasonic measurements can be taken at any time regardless of the LOC(ation) or MACH(ine) settings. When taking measurements, the 9U-7981 Couplant must be applied to the sensing end of the probe before measuring component. 4. To couple the ultrasonic probe to a component, it is important to have the 9U-7981 Couplant between the sensing end of the probe and the component. The probe tip surface must be flat (square) with the part being measured. It may be easier to hold the probe properly if a finger is held on top of the probe.

g02902123

Example of BUSHING TOOL with type of tool used: CALIPER

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.

Illustration 36

6. Saving ultrasonic measurements can be done either while holding the probe on the part or after removing the probe. If you prefer to remove the probe before pressing “SAVE” , pull off the probe quickly to prevent the measurement from increasing slightly as the probe is removed.

g02902124

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

19

Undercarriage Measurement Techniques Track Links

Illustration 39

g02902176

Probe Located On The Tip Of The Grouser

2. It may be easier to measure from the tip of the grouser to the bottom of the plate. Illustration 37

g02902162

3. On double grouser and triple grouser shoes, do not measure the rear grouser due to interference with the trailing edge.

Measuring Track Links

4. On regrousered shoes, it may be necessary to use a depth gauge or take ultrasonic measurements from the tip and the bottom of the plate and add the readings together, since the weld does not completely penetrate.

1. Measure distance from tread surface to bushing bore. 2. Place probe over the center line of the bushing. 3. Slide the probe along the tread surface and take the smallest reading.

Track Bushing

Track Shoes

Illustration 40 Illustration 38

g02902196

g02902164

1. Measure the wall thickness.

Probe Located On The Bottom Of The Plate

2. Slowly slide the probe around the reverse drive side to find the smallest dimension and save this measurement.

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

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.

20

Idler

Illustration 41

Illustration 43

g02902204

Illustration 44

g02902206

g02902201

1. Measure the center flange thickness only on fabricated idlers. Determine center flange wear from the idler wear charts in the CTS Handbook. 2. Use conventional depth gauge to measure wear on the tread surface. 3. Add center flange wear to the depth gauge, measurement before determining percent worn.

Carrier Roller Three Piece Rims

Measure Distance From The Outside Of Tread Surface To The Bore

Note: Due to the use of tapered roller bearings, more than one thickness can be found along each tread surface. It is important to place the probe on the outer half of the tread surface on the side of the roller opposite the shaft. Note: The Ultrasonic Wear Indicator III will not measure cast iron rollers. Some D3, D4, D5, and D6 Tractors or 225 Excavator carrier rollers are cast iron.

Illustration 42

g02902205

Measure the Thickness Of Press-On Rim

21

Track Roller

Note: In addition to measuring steel parts, many other materials can be measured. However, to accurately measure these materials, the velocity setting of the Indicator III must be changed. Refer to the Section “Ultrasonic Velocity Adjustment” in this manual for complete information other than steel. 1. Install 168-7722 or 4C-5485 Probe, and calibrate the Indicator III and probe. Refer to the Section “Ultrasonic Velocity Adjustment” in this manual. When taking measurements, the 9U-7981 Couplant must be applied to the sensing end of the probe before measuring.

Illustration 45

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.

g02902237

1. Measure the distance from the tread surface to the bore. 2. Do not measure to the retainer bolt holes on H, N, and L series Track-Type Tractors and current Track-Type Loaders. Observe the location of the retainer bolts and place the probe between them. On low sprocket Track-Type Tractors, earlier Type Loaders, and Excavators the retainer bolts are not visible. Observe the thickness measured value closely from roller to catch any abnormally small thickness which would indicate a reading to the bolt hole.

3. To check the accuracy of the reading, measure a piece of the same type of material of known thickness. If the reading is not correct, the velocity may be adjusted to make the Indicator III read accurate. Refer to the Section “Ultrasonic Velocity Adjustment” in this manual.

Transferring the Memory Values To or From a Computer

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.

The information contained (saved) in the Indicator III memory may be transferred to an IBM or compatible personal computer for storage or printing using the Custom Track Service (CTS) personal computer program.

Competitive Parts

When transferring machine data from an IBM or compatible personal computer using the Custom Track Service (CTS) program:

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.

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.

Measuring the Thickness of Parts Other than Undercarriage

2. The user can select where the machine data will be stored in the Indicator III by scrolling to the Machine No. before the transfer. The Indicator III will then store the transferred data from the machines beginning with the MACH(ine) No. shown on the Indicator III display.

In addition to measuring undercarriage wear, the Ultrasonic Wear Indicator III can be used to measure steel part thickness without changing any settings. This is simple to do because the wear indicator is designed to show the MEASURED VALUE regardless of which keys have been pressed. This allows a nonexperienced person to take readings.

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.

Examples where this may be used to check the wall thickness of a: • Bulldozer blade • Bucket base edge • Scraper bowl

22

Note: When transferring machine data from a PC to the Indicator III, the Indicator III does not wrap around the 64 MACH(ine) locations. The data from three machines is transferred from the PC, MACH(ine) memory in the Indicator III is not empty, and the Indicator III displays MACH(ine) 63. The first machine transferred will be stored in MACH(ine) 63, the second machine transferred will be stored in MACH(ine) 64, and the third machine will overwrite the second machine and be stored n MACH(ine) 64.

23

Settings Menu

Illustration 46

24

g02902257

Settings Menu Operation (Default States Shown)

25

Illustration 47

g02902259

Settings Menu Operation

26

Beeper

The Settings Menu is a special menu to change specific functions for the wear indicator. Enter the Settings Menu by pressing and releasing the blue “SHIFT” key and then pressing the “SAVE/SET” key. The Settings Menu flow chart is shown as Figure 46. The Settings Menu contains these functions in this order: Resolution, Turnoff, Velocity, Serial, Beeper, Language, Distance, and Date. Resolution is the first function displayed when entering the Settings Menu. Press the up down arrow to scroll forward through the Settings Menu or up arrow to scroll backwards through the Settings Menu. Figure 47 shows the different settings that can be selected with each function in the Settings Menu.

This function turns ON or OFF the beeper that sounds when the probe is properly coupled to the material being measured. When turned OFF, coupling will still be indicated any MM or IN being displayed beside the MEASURED VALUE when properly coupled. 1. ON (default position). 2. OFF.

Language

Resolution

This function allows the language to be changed. All of these languages are in the 168-7721 Ultrasonic Wear Indicator III and are selectable.

Allows the measurement resolution to be in a high or a low mode.

1. ENGLISH (default position). 2. FRENCH.

1. Low Resolution mode (default position) is 0.0 mm (0.00 inch).

3. GERMAN.

2. High Resolution mode is 0.00 mm (0.000 inch)

4. PORTUGUESE.

Turnoff

5. SPANISH.

This function allows for longer battery life by automatically turning the Indicator III OFF if it has not been used for 5 minutes. Normal operation of the key pad ON/OFF switch is not affected.

Distance Allows the units for distance to be changed: 1. MILES (default position).

1. MANUAL - Indicator III only turns OFF by using the “ON/OFF” key switch.

2. KM - Kilometers.

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.

Date This function allows date configuration to be selected: 1. MM/DD/YYYY - Month, Day, Year (default position).

Velocity

2. DD/MM/YYYY - Day, Month, and Year. Allows the ultrasonic velocity to be viewed on the display and changed using the front panel key pad.

Ultrasonic Velocity Adjustment

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

Adjustment of the velocity calibrates the Indicator III so it can be used accurately to measure the thickness of materials other than undercarriage steel.

2. ON - Velocity adjust enabled.

Serial

Ultrasonic Velocity is the speed in Millimeters per microsecond (MM/uSEC) or inches per microsecond (IN/uSEC) that sound travels through different materials.

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:

Refer to Table 6 for a list of various materials, ultrasonic velocities, and probe calibration values.

1. 1200. 2. 9600 (default position). 3. 19200.

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Table 6 Velocity MM/uSEC (IN/uSEC)

Probe CAL1 Measured Value

Aluminum

6.09 mm (0.240 inch)

6.3 mm (0.25 inch)

Cast Iron

4.57 mm (0.180 inch)

4.8 mm (0.19 inch)

Copper

4.57 mm (0.180 inch)

4.8 mm (0.19 inch)

Example of Screen Display with VEL in IN/uSEC

Glass

5.33 mm (0.210 inch)

5.6 mm (0.22 inch)

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

Mild Steel

5.84 mm (0.230 inch)

6.3 mm (0.25 inch)

Plastic (Plexiglass)

2.67 mm (0.105 inch)

2.8 mm (0.11 inch)

Stainless Steel

5.84 mm (0.230 inch)

6.3 mm (0.25 inch)

Tin

3.30 mm (0.130 inch)

3.6 mm (0.14 inch)

5.87 mm (0.231 inch)

6.3 mm (0.25 inch)

Material

Undercarriage Steel

Illustration 49

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If the number is not correct, or you plan to measure other materials, the velocity number can be changed. Refer to the Section “Changing the Ultrasonic Velocity”.

Changing the Ultrasonic Velocity 1. Locate the velocity number for the material to be measured in Table 6. The numbers given in Table 6 are approximate, and slightly different numbers may need to be used to give accurate readings because of differences in material composition.

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.

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

Checking the Ultrasonic Velocity

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.

1. Enter the Settings Menu and change the VELOCITY from OFF to ON (refer to the Section “Settings Menu”).

4. Calibrate the probe for this new material by pressing the PROBE CAL key. Then place the probe, with couplant applied to the sensing end of the probe, on the calibration disk. The number shown as the MEASURED VALUE on the display should be the value shown on the Velocity Table under PROBE CAL. MEASURED VALUE for the new material. Every time the calibration disk is measured with this new velocity setting, this reading should appear on the MEASURED VALUE display instead of 6.3 mm (0.25 inch).

2. With the Indicator III ON, make sure that display is in the MACH(ine) display mode, then press the MM/INCH key. The velocity setting of the Indicator III will appear on the bottom line of the display, as shown below. Either MM or IN will be displayed, depending on which was being used earlier.

5. Measure a known thickness of the new material with the Indicator III to be sure that the readings are accurate. 6. If the readings are not exact, change the velocity setting number right-hand digit by one and recalibrate. Illustration 48

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7. Measure the material again and continue this process until the Indicator III reads correctly.

Example of Screen Display with VEL in MM/uSEC

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Battery Level Monitor

Return to Last Menu Screen

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

The Indicator III will remember the last MACH(ine) or LOC(ation) Display Mode screen that was displayed when the Indicator III was last turned OFF. If the Indicator III was turned OFF in the Settings Menu or showing the Battery Level Monitor screen, then it will display the last MACH(ine) or LOC(ation) Display Mode screen when the Indicator III was last powered up. The Machine or Location Display Mode screen will not be remembered if a factory reset was performed or if the Indicator III was abnormally powered down. For example, by pulling out batteries while the Indicator III is ON.

Factory Reset

Illustration 50

This function will reset the Indicator III back to the state it was in when it left the factory. The reset will destroy all stored data and completely reset all parameters in the Settings Menu to the default states. To reset, the Indicator III must be OFF. Then, press and hold the “CLR” and “ON/OFF” keys at the same time for at least 3 seconds. The Indicator III will turn ON and will display “"FACTORY RESET” while the factory reset is being performed.

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Note: If using NiCad rechargeable batteries, the batteries must be fully charged before each use for the Battery Level Monitor to work correctly. Refer to the Section “Charging the Internal NiCad (rechargeable) Batteries”.

Viewing the Software Version Screen The version number of the software used in the Ultrasonic Wear Indicator III can be viewed on the display in the following manner.

Low Battery Indication The LCD display will flash for at least 30 seconds when the battery voltage reaches 6.14 V, which is when a minimum of 2 hours of battery life is left. It will then stop flashing for about 30 minutes and return to at least a 30 second flashing period. When the Indicator III has reached a minimum of 1 hour of remaining battery life, the display will flash and continue to flash until the power is increased by charging the NiCad batteries or installing new alkaline batteries. The Indicator III shuts down when the battery voltage reaches approximately 5.12 V.

1. Turn the Indicator III OFF. 2. Press and hold the “LOC/MACH” key, then press “ON/OFF” to turn the Indicator III ON.

Note: If using NiCad rechargeable batteries, the batteries must be fully charged before each use for the Low Battery Indication to work correctly. Refer to the Section “Charging the Internal NiCad (rechargeable) Batteries”.

Illustration 51

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Example of Screen Display For SOFTWARE VERSION Number

Note: When the probe is coupled and the Indicator III battery power is low, the beeping sound will be heard at half rate. The beeping sound occurs when the entire display flashes during a low battery indication.

3. When the Indicator III comes ON, the Software Version screen is displayed, as shown in Step 2. To leave this screen, turn the Indicator III OFF. The software is the program that operates the microprocessor in the Indicator III. It is contained nonvolatile, located in the Indicator III, so removing the batteries for an indefinite time will not affect the memory.

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Checking the Operation of the Indicator III The following procedure may be used to check the operation of the 168-7721 Ultrasonic Wear Indicator III and the 168-7722 and 4C-5485 Probe. The only components required for the test are the 168-7721 Ultrasonic Wear Indicator III, 168-7722 and 4C-5485 Probe, and 9U-7981 Couplant. Perform all the procedures, as shown in the Section “Operating Instructions for 168-7721Indicator III”, in this manual. Instead of measuring undercarriage components, the metal calibration disk should be measured and the MEASURED VALUE saved, and the MEMORY VALUE displayed to check for accurate readings. Alternate Method An alternate method is to measure a known thickness of undercarriage steel. Illustration 52

1. Check the display of the undercarriage storage locations for one machine. During this test, use all front panel keys to be sure that the panel keys operate correctly.

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Cover Removed To Access The Gain And Display Contrast adjustments

(1) RP1 Gain Adjustment (2) RP2 Display Contrast Adjustment

2. Locate contrast adjustment, Figure 52 on the top of the printed circuit board. It is one of only two screwdriver adjustments and is located below the calibration block and is labeled RP2 on the printed circuit board.

If the Indicator III does not operate properly during this test, refer to the Section “Troubleshooting” in this manual. 2. Next, test the Indicator III on actual undercarriage components. Correct measurements should appear on the MEASURED VALUE display without having to move the probe back and forth.

3. Before turning this adjustment, observe the position of the screwdriver slot to see if it is marked. Place a mark on the small plastic case if the position is not already marked. This is the factory setting of the display contrast. Marking this position will allow you to return it to its original setting, if desired.

3. Also check to see that measurements can be taken on thick undercarriage components such as through track shoe grouser bars. 4. If the Indicator III has trouble making any of these readings, the gain may need to be adjusted. Refer to the Section “Troubleshooting” in this manual for the procedures to adjust the gain.

4. To adjust the display contrast, use a small flat head screwdriver to turn the contrast while viewing the display screen. Continue to adjust until the information on the screen is clear to the user preference. Once the setting is obtained, replace the rear cover.

5. This completes the test of the Indicator III.

Adjusting the Display Contrast

Adjusting the Gain

The display contrast may be adjusted to the users preference. The contrast has been set at the factory. If the contrast needs to be changed, use the following procedures:

If the gain is out of adjustment, it will result in inaccurate or hard to get readings, or no echo. If the gain needs to be changed, use the following procedures:

1. Remove six screws from the back cover and remove the cover.

Note: The gain adjustment is set at the factory using precision instruments and should not be changed unless necessary. 1. Remove six screws from the back cover and remove the cover. 2. Locate gain adjustment, Figure 52, on the top of the printed circuit board.

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3. Before turning this adjustment, check and see if the position is marked. If not marked, place a mark on the small plastic case. This is the factory setting of the gain adjustment which was set using instruments. Marking this position will allow you to return to original setting if you have trouble with the operation of the Indicator III during this procedure.

If you have another probe that is known to be good, try it and see if it works. If not, use the following procedures:

4. Make sure that the beeper is ON, which is selected as ON or OFF in the Settings menu.

3. Turn the Indicator III ON.

1. Take the Indicator III to a quiet place. 2. Put the probe close to your ear.

4. You should hear a high frequency sound emitted by the probe.

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.

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.

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.

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.

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.

Undercarriage Measurement Display Map Note: Settings menu in default states.

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 with new alkaline batteries. As the rechargeable batteries age, they will provide less operating time for the Indicator III. When the operating time between charging is unacceptable, the batteries should be replaced with new NiCad batteries. Note: The longest life will be obtained by charging the batteries only after the display is flashing, indicating the batteries are fully or near being discharged. If the Battery Level Monitor shows that the batteries have sufficient power remaining and the Indicator III still will not turn ON, it must be sent in for repair. Refer to the Section “Service” in this manual. If the display comes on but the Indicator III will not take measurements, the problem may be in the probe.

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Illustration 53

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32

Location Display Map Note: Settings menu in default states and units are inches.

33

Illustration 54

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34

Illustration 55

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9U-7981Couplant Material Safety Data Sheet (To comply with 29 CFR 1910, 1200) Effective Date: 2/98 N/A = not applicable or not available Section 1 - Product Identification

Illustration 59

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Section 5 - Reactivity Data

Illustration 56

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Section 2 - Hazardous Ingredients

Illustration 60

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Section 6 - Health Hazard and First Aid Data Illustration 57

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Section 3 - Physical Data (nominal)

Illustration 61

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Section 7 - Storage and Handling Information Illustration 58

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Section 4 - Fire and Explosion Hazard Data

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Illustration 62

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Section 8 - Control Measures

Illustration 63

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Service If the Ultrasonic Wear Indicator III does not operate correctly, recharge or replace the internal NiCad batteries with new ones and check the operation. If it still does not operate, refer to the Section “Troubleshooting” in this manual. If the Indicator III is found to be faulty, contact Dealer Service Tools for information on how to obtain the needed repair service. Dealer Service Tools provides the instrument user with a warranty of 1 year from purchase date. If the reason for failure is determined to be abuse, the warranty is declared void. Any out-of-warranty repairs will be charged to the owner. ■

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©2013 Caterpillar All Rights Reserved

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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

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