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

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NEHS0730-0311 September 2013

Tool Operating Manuali04778305

168-7720 UltrasonicWearIndicator III GroupSMCS Code: 0374; 0599; 0729; 0787

Caterpillar ProductsAll

Table of ContentsIntroduction ...........................................................2Literature Information .............................................2Safety Section....................................................2General Information Section ................................3Operation Section...............................................3Maintenance Section ..........................................3Service Parts Section..........................................3Safety Icon Nomenclature ...................................3Personal Protection/ImportantInformation....................................................3Prohibited Action.............................................3Hazard Avoidance...........................................3

General Information ...............................................3Introduction........................................................3Additional Contact Information.............................4Other Uses for The Indicator III ............................4Benefits Ultrasonic Wear Indicator III ....................4Features of the Indicator III...............................4

General Measurement Benefits............................4Undercarriage Measurement Benefits ..................5

168-7720Ultrasonic Wear Indicator IIIGroup..................................................................5Storage Of Conventional Tools ............................5Optional Items....................................................6168-7720UltrasonicWear IndicatorIII Group Specifications.........................6168-7722Ultrasonic ProbeSpecifications ...................................................7156-1077Power InverterSpecifications ...................................................7Connections to the 168-7721Indicator III.............8168-7721Indicator IIIDescription.......................................................8Abbreviations and Descriptions Used onFront Panel and Key Pad ...............................8

Charging the Internal NiCad (rechargeable)Batteries ........................................................10Procedure.....................................................10Replacing The Internal RechargeableBatteries ..................................................... 11

Connecting To DC power...................................12Care and Cleaning Of 168-7721IndicatorIII...................................................................13Remove the 9U-7981Couplant Residue ............13Cleaning the Case and Front Panel KeyPad ............................................................13Care of Connectors .......................................13

Operating Instructions for 168-7721IndicatorIII ......................................................................13Turn the Indicator III ON ....................................13Calibrating the Indicator III Probe .......................14Undercarriage Measurement Procedure .............15Clearing The Memory........................................15Using LOC(ation) Mode of Operation..................16List of Undercarriage Storage LOC(ation)Displays......................................................16

Entering Information into the Indicator III .............17Changing Displays with Words ..........................18Measuring Track Sag ........................................18Taking Ultrasonic Measurements .......................18Saving Measured Values in Memory...................19Tool Displays....................................................19Measurement Operating Tips.............................19

Undercarriage Measurement Techniques...............20Track Links ......................................................20Track Shoes.....................................................20Track Bushing ..................................................20Idler.................................................................21Carrier Roller....................................................21Three Piece Rims..........................................21

Track Roller......................................................22Competitive Parts .............................................22Measuring the Thickness of Parts Other thanUndercarriage.................................................22

Transferring the Memory Values To or From aComputer ..........................................................22Settings Menu .....................................................24Resolution........................................................27Turnoff.............................................................27Velocity............................................................27Serial...............................................................27Beeper ............................................................27Language ........................................................27

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Distance ..........................................................27Date ................................................................27

Ultrasonic Velocity Adjustment ..............................27Checking the Ultrasonic Velocity ........................28Changing the Ultrasonic Velocity........................28Battery Level Monitor ........................................29Low Battery Indication.......................................29Return to Last Menu Screen ..............................29Factory Reset...................................................29Viewing the Software Version Screen .................29Checking the Operation of the IndicatorIII...................................................................30Alternate Method...........................................30

Adjusting the Display Contrast ...........................30Adjusting the Gain ............................................30

Troubleshooting...................................................31UndercarriageMeasurement Display Map..............31Location Display Map...........................................339U-7981CouplantMaterial Safety DataSheet ................................................................36Service ...............................................................37

IntroductionImportant Safety Information

Illustration 1 g02139237

Think Safety

European Union Compliant, CE Marked

Most accidents that involve product operation,maintenance, and repair are caused by failure toobserve basic safety rules or precautions. An accidentcan often be avoided by recognizing potentiallyhazardous situations before an accident occurs. Aperson must be alert to potential hazards. This personshould also have the necessary training, skills, andtools to perform these functions properly.

Improper operation, lubrication, maintenance, orrepair of this product can be dangerous and couldresult in injury or death.

Do not operate or perform any lubrication,maintenance, or repair on this product until youhave read and understood the Tool OperatingManual.

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

The hazards are identified by the “Safety AlertSymbol” and followed by a “Signal Word” such as“DANGER”, “WARNING”, or “CAUTION”. The SafetyAlert “WARNING” label is shown below.

A non-exhaustive list of operations that may causeproduct damage are identified by “NOTICE” labelson the product and in this publication.

Caterpillar cannot anticipate every possiblecircumstance that might involve a potentialhazard. The warnings in this publication and onthe product are, therefore, not all inclusive. If atool, procedure, work method, or operatingtechnique that is not recommended by Caterpillaris used, the operator must be sure that theprocedures are safe. The operator must also besure that the product will not be damaged or madeunsafe by any unspecified procedures.

The information, specifications, and illustrations in thispublication are based on information that wasavailable at the time that the publication was written.The specifications, torques, pressures,measurements, adjustments, illustrations, and otheritems can change at any time. These changes canaffect the service that is given to the product. Obtainthe complete and most current information before youstart any job.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpillarreplacement parts or parts with equivalentspecifications including, but not limited to,physical dimensions, type, strength, and material.

Literature InformationThis manual contains safety information, operationinstructions and maintenance information and shouldbe stored with the tool group

Some photographs or illustrations in this publicationmay show details that can be different from yourservice tool. Guards and covers might have beenremoved for illustrative purposes.

Continuing improvement and advancement of productdesign might have caused changes to your servicetool, which are not included in this publication.

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

Safety Section

The Safety section lists basic safety precautions.

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Read and understand the basic precautions listed inthe Safety section before operating or performingmaintenance and repair on this service tool.

General InformationSection

The General Information section describes toolingfunctions and features. The section provides usefulinformation on individual parts, additional tooling, andresources.

Operation Section

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

Photographs and illustrations guide the operatorthrough correct procedures for using the tool group.

Operating techniques outlined in this publication arebasic. Skill and techniques develop as the operatorgains knowledge of the service tool and the toolscapabilities.

MaintenanceSection

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

Service Parts Section

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

Safety Icon Nomenclature

Personal Protection/Important Information


Personal Protection/Important Information

Prohibited Action

No smoking –

Hazard Avoidance

Crushing hazard (foot) –

Crushing hazard (hand) –

Pinch point –

Fire hazard –

Electrical Shock - Hazard –

Fire hazard –

General Information

Introduction


168-7721Ultrasonic Wear Indicator III

The 168-7720Ultrasonic 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. Theindicator also guides the operator by indicating theundercarriage components to be measured. Thethickness values can be stored in internal memory forrecall later. This stored informationmay be transferredto a computer for printing.

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The Custom Track Service (CTS) personal computerprogram is available and when used with theUltrasonic 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 the partthickness by sensing high frequency sound wavesthrough the material to be measured. When the soundreaches the opposite side of the part, sound isreflected back and received by the probe. The timerequired for the sound to travel through the part andbe received determines the thickness of the part. Themicroprocessor in the Indicator III converts the timeinto a thickness value and displays value.

When taking measurements. The 9U-7891Couplantmust 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 to theside of the Indicator III.

Additional Contact Information

For additional product support questions concerningthis tool, contact the Caterpillar Dealer Service ToolsHotline at:

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

Other Uses for The Indicator III

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

Benefits UltrasonicWear Indicator III

For 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 mountelectronics for high reliability.

• For battery access - loosen the two battery coverscrews on the back of the Indicator III.

• Backlit Liquid Crystal Display can be turned ON orOFF.

• Power Level Monitor shows estimated batterypower remaining in percent.

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

• Built-in multiple language capability with English,Portuguese, French, Spanish, and Germanlanguages. Programmodules no longer needed toswitch languages.

• 168-7720Ultrasonic Wear Indicator III Groupincludes an updated probe with a longer, moredurable cable.

• Used with Custom Track Service (CTS)inspections, which can be downloaded directly to acomputer for viewing or printing.

• Uses five Alkaline or NiCad AA batteries (nobattery pack).

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

• When transferringmachine data from a PC to theIndicator III, the user can select where the data willbe stored.

General Measurement Benefits

• Higher accuracy measurements. Digital display ofthickness is accurate to 0.10 mm (0.004 inch) forlow-resolution mode, and 0.01 mm (0.0004 inch)for high-resolution mode.

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

• Easy to use. Thickness reading will always appearon the display when the probe is used, regardlessof mode of operation.

• Calibrated for undercarriage steel, but velocity canbe adjusted to measure other materials such asaluminum, plastic, and glass.

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

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

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UndercarriageMeasurement Benefits

• Less time cleaning parts. Only a small surface onthe wear area must be cleaned. On bushings, theback side, between the bushing and shoe, doesnot 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 projected life.

• Prompts CTS inspector on next reading location.

168-7720UltrasonicWear IndicatorIII Group


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

Table 1

168-7721UltrasonicWear 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 VAC, 50/60Hz)

(continued)

(Table 1, contd)

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

- NEHS2835 168-7720Group Label (located in lid ofcarrying case)

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

- NEHS0730 UltrasonicWear Indicator III Group ToolOperatingManual

Storage Of Conventional Tools


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

Table 2

Storage Locations


(1) PEKP9400 Custom Track Service Handbook: Fitsunder Indicator III

(2) 5P-3277 Tape Measure: 3 m (9.8 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 (11.8 inch), store ontop of 9U-6000Paper Towels

Conventional CTS tools can be stored with the168-7720Ultrasonic Wear Indicator III Group.Because some undercarriage components cannot bemeasured with the 168-7721Ultrasonic WearIndicator III, provisions have been made for storingthe required conventional CTS tools in the carryingcase. These tools are not provided with the group, butmay be ordered separately.

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

Optional Items


Optional Items For 168-7721UltrasonicWear Indicator III

Table 3

Optional Items


(1) 4C-5488 Cable Assembly RS232 (PC AT Ver-sion): For connecting the 168-7721 toan IBM AT, or compatible, personal com-puter. Has 9-pin, type D connector(DB9F).

(2) 4C-5489 Cable Assembly RS232 (PC XT Ver-sion): For connecting the 168-7721 toan IBM XT, or compatible, personal com-puter. Has 25-pin, type D connector(DB25F).

(3) 4C-5897 Cable Assembly RS232 (ModemCable):For connecting the 168-7721 to a mo-dem which transfers data over telephonelines to a personal computer.

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

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

(6) 156-1077 Power Inverter: For powering the168-7721 from 12 VDC and includesbattery cables and a cigarette lighter.

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

- - Custom Track Service (CTS) softwareprogram for transferring stored measure-ments from the 168-7721 to an IBM PC,or compatible, computer for storage orprinting. Also required when a modem isused.

(continued)

(Table 3, contd)

- - Additional Service Replacement Part(not shown)

- 4C-5490 Couplant Holder: The service replace-ment for the holder that stores the9U-7981Couplant container.

Note: Five batteries are required to power the168-7721Ultrasonic Wear Indicator III.

NOTICEDO NOT attempt to recharge alkaline batteries usingthe 4C-3024Battery Charger.

Attempting to charge an alkaline battery can result indamage to the 168-7721 Ultrasonic Wear IndicatorIII.

Place a piece of tape over the charge connector, toprevent charging, when using alkaline batteries.


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

168-7720UltrasonicWear Indicator IIIGroup Specifications

Power 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 back cover. See the Section“Replacing The Internal Rechargeable Batteries” forthe procedure.

NOTICEDO NOT attempt to recharge alkaline batteries usingthe 4C-3024Battery Charger.



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

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

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

Approximate Battery Life (with Indicator III backlightand beeper ON)

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

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

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

Power Line Operation:

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

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

Measuring Resolution:

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

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

Measurement Accuracy:

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

High Resolution ± ....................0.076 mm (0.003 inch)

Operating Temperature: ..........................−18° to 60°C(−0.4° to 108.0°F)

Storage Temperature:

Without Batteries Installed.......................−40° to 60°C(−40.0° to 108.0F)

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

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

Memory Size:

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

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

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

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

Weight:

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

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

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

168-7722UltrasonicProbe Specifications

Probe Type .................Dual Element 7.5 MHz specialapplication

Probe Size:

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

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

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

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

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

Includes Certificate of Conformity

156-1077Power Inverter Specifications

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

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

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

Output ...........................................................115 VAC

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

Over Temperature Protection: ..........When the powerinverters internal heat sinks reach 65.5°C (150 °F),the inverter will automatically shut down. The invertermay be “restarted” by first disconnecting the inverterand allowing to cool for 15 minutes beforereconnecting.

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

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

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

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

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

MaximumContinuous power ............................300 W

Surge Capability (Peak Power) ........................600 W

Overload Protection ........ Inverter automatically shutsdown if continuous power is greater than 300 W

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Connections to the 168-7721Indicator III


Connectors For 168-7721 Indicator IIIRefer to Table 4 for item identification.

Table 4

Connectors For 168-7721 Indicator III


(1) 9U-7981 CouplantStored in pump-type dispenser. A smallamount of couplant must be applied to thesensing end of the 168-7722UltrasonicProbe, before measuring, to couple ultra-sonic sound into the material beingmeasured.

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

(3) - Steel Calibration DiskThe disk is used to check the accuracy ofthe wear indicator and recalibrate the wearindicator, if necessary. For additional infor-mation, refer to the Section “Calibrating theIndicator III Probe” in this manual.

(4) RS232 Connector (shown without 1 9/16 inch pro-tective cap installed) Used to connect4C-5488Cable Assembly RS232 (PCAT) or 4C-5489Cable Assembly RS232(PC XT) or 4C-5897Cable AssemblyRS232 (ModemCable) These cables canbe used to transfer stored undercarriagedata from the 168-7721 to a personalcomputer or printer. Refer to the Section“Optional Items” in this manual, for eachcables-specific function and software pro-gram requirements.

(5) - Charger ConnectorUsed to connect the Battery Charger whenrecharging the rechargeable Batteries (Ni-Cad). Also used to power the 168-7721with the 4C-3024Battery Charger. Theplug of the 4C-3024 can be plugged intothe 156-1077 Power Inverter to provide12 VDC power for powering the indicator.

(continued)

(Table 4, contd)

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

(7) - Earphone Connector (mono)Used to connect earphone to hear beeperssound in noisy environments. The beepercan only be heard when an earphone jackis installed in the earphone connector.

168-7721Indicator III Description


168-7721 Indicator III Front Panel And Key Pad

Abbreviations and Descriptions Used on FrontPanel and Key Pad

1. MACH:

Machine, referred to as MACH(ine) in this manual.

2. 6.3 mm (0.25 inch):

Describes the metal calibration disk thicknessmeasured in millimeters and inches during probecalibration (metal calibration disk is located on toppanel).

3. RS232:

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Identifies connector located on top panel whichprovides the RS232 signal connection, for theoptional cables, for transferring data to a personalcomputer. Refer to the Section “Optional Items” inthis manual for each cables-specific function,software requirements, and use with the168-7721 Indicator III.

4. CHARGE:

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

5. PROBE:

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

6. LOCATION & LOC:

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

Description of Displays and Keys

7. MACH(ine) DISPLAY:

Identifies the machine number (from 1 to 64)corresponding to the information on the display.When data is saved, data can be located later bygoing to this machine number.

8. LOCATION Display:

Shows the undercarriage storage LOC(ation)display selected by the up or down arrow keys andshows the machine model when in the MACH(ine)mode of operation. The display, in Figure 9, is inthe LOC(ation) mode.

9. MEASURED VALUE:

Displays the thickness value being measured orthe value of the last measurement taken. MM or INwill appear to the right of the value displayed, whenmeasuring, to show that the probe is properlycoupled to the material.

10.MEMORY VALUE:

Displays the stored value for the location shownunder MACH and LOCATION when in the LOC(ation) mode of operation. The machine serial(product identification) number is displayed herewhen in the MACH(ine) mode of operation.

11.SAVE/SET:

This key will provide one of two functions:

SAVE:

Press to store the MEASURED VALUE in theMEMORY VALUE location. After the value issaved, the display will automatically advance to thenext LOCATION.

SET:

Press and release the blue SHIFT key and thenthe SET key to enter the Setting Menu. Perform thesame keystrokes to exit the Settings Menu.

12.MM/IN:

Changes the display values fromMM (millimeter)to IN (inch) and will work only when a value is onthe display. Also used to show ultrasonic velocity.Refer to the Section “Velocity” in this manual.

13.PROBE CAL:

Calibrates the ultrasonic probe so the Indicator IIIwill read accurately.

To use, apply couplant to the sensing end of theprobe and press probe to the metal calibration diskon top of the Indicator III.

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

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

Refer to the Section “Calibrating the Indicator IIIProbe” and the Section “Ultrasonic VelocityAdjustment” 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 be disabledin the Settings Menu. Refer to the Section“Settings Menu” in this manual.

15.CLR/CLR MACH:


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 and thenCLR MACH key to enter the CLR MACH screen. Thetop line of the display will show CLR MACH and thenthe number of the machine to be cleared. Press theVALUE key to clear this machine. To clear allmachines, first press the up or down arrow key tomove the cursor to the bottom line of the displayshowing CLR ALL MACH. Press the VALUE key.

16.LOC/MACH:

Changes from the MACH(ine) mode to the LOC(ation) mode of operation. In the MACH(ine) mode,the LOCATION display will show the letters MACH.

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

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In the LOC(ation) mode, the LOCATION displaydoes not show the letters MACH, but insteaddescribes the inspection information orundercarriage measurement location.

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

17.LEFTARROW, A or B:


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

When preceded by pressing either the red or blueSHIFT key, the corresponding colored character isentered on the display.

18.UPARROW / BACKLIGHT:


UPARROW:

If LOCATION display reads MACH:

Press the up arrow key to advance to the nextMACH(ine) number. This is the MACH(ine) modeof operation.

If LOCATION display does not read MACH, pressthe 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 the MACH(ine) orLOC(ation) Display Mode.

BACKLIGHT:

Press and release the blue SHIFT key, then pressthis key to turn ON the display backlight. Performthe same keystrokes to turn the backlight OFF.

Note:When Ultrasonic Wear Indicator III is in ManualTurn off mode (selectable in the settings menu): Ifbacklight is ON, no key has been pressed, and probenot coupled for 5 minutes, then the backlight will turnOFF. The backlight will automatically turn ON when akey is pressed or probe is coupled.

19.DOWN ARROW:

Use to move the display in the opposite directionas the up arrow.

Note: Arrow keys will change display once every timepressed or may be held down to scroll (change) thedisplay at a faster rate.

20.VALUE and RIGHTARROW:

VALUE: Used for manual entry of values when inthe LOC(ation) mode. When pressed, a digit on thedisplay 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

RIGHTARROW:

Used to move the flashing cursor to the right onecharacter 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 key pad.

22.SHIFT (red):

Used to enter any red character from the key pad.

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 to enterinto storage when in the LOC(ation) mode.

Charging the Internal NiCad(rechargeable) Batteries


Rear View Of 4C-3024Battery Charger

The 168-7720Ultrasonic Wear Indicator III Group issupplied with a 4C-3024Battery Charger(1) and fiveNiCad (Nickel Cadmium), Rechargeable Batteries,size AA.

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

Procedure

1. Move switch (1) on the rear of 4C-3024BatteryCharger(2) to the correct AC line voltage, either120 V or 230 V, depending on use.

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

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

Note: For operation outside the USA, an AC powerplug adapter may be required.

4. Turn the Indicator III ON to check if the batteriesare being charged. It may be necessary to wait afew 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 are charged.

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 only afterthe display flashes or goes blank, indicating thebatteries are near or fully discharged.

Replacing The Internal Rechargeable Batteries

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

The batteries can be replaced with new 1U-7445Batteries when the batteries no longer give sufficientoperating time. The batteries can be replaced with1U-9533 Alkaline Batteries (non-rechargeable).

Note: The internal batteries can be removedindefinitely and the internal memory values will not beaffected.

NOTICEDO NOT attempt to recharge alkaline batteries usingthe 4C-3024 Battery Charger.




Back View Of 168-7721UltrasonicWear Indicator III

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


Indicator III With Battery Cover Removed

2. Remove battery cover (2).

3. Remove all batteries (3) and replace with newbatteries.


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

12


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

4. To install new batteries: The (+) terminal of thebattery must be placed on the battery contact withthe (+) symbol (4) (in the recessed area of thebattery compartment, as shown in Figures 13 and14 ).

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


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

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

Connecting To DC power


156-1077Power Inverter(1) Power Inverter (2) Cigarette Lighter Adapter (3) Manual (4)Battery Power Clips Attached To Cable (5) Installed Fuse (6) ExtraFuses (7) Two Outlets That Accept The Power Cables PlugSuppliedWith The Emission Analyzer (8) ON/OFF Switch

1. The optional 156-1077Power Inverter (12 VDC)may be used to connect the 168-7721 Indicator toan external DC power source.

2. Plug the power plug of the 4C-3024BatteryCharger into one of the two outlets on the156-1077Power Inverter. Refer to Figures 10and 16.

3. When using the battery from a machine or engineas the power source, power the emission analyzerby connecting the power cable clip with the blackcolored handle to the machine or engines frame orto the battery negative terminal. Connect the powercable clip with the red colored handle to the batterypositive terminal.

NOTICEThe 156-1077 Power Inverter requires a 12 VDC in-put. Make sure not to exceed this specification or thepower inverter fuse may blow resulting in possibledamage to the power inverter. Also, reverse polaritycould damage the power inverter, but will most likelyblow the 35 A fuse. Refer to item (5) Figure 11.

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

13

Care and Cleaning Of 168-7721IndicatorIII

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

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

Keep the Indicator III stored in the carrying case whennot in use.

Remove the 9U-7981CouplantResidue

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

The couplant is water soluble and a damp cloth canbe used to remove any residue that has dried. Caremust be taken so no water enters the Indicator IIIcase.

Cleaning the Case and Front Panel Key Pad

NOTICEDO not use aromatic hydrocarbons or chlorinated sol-vents for cleaning. These chemicals will react with theplastics used in the case and cause damage.

Care of Connectors

The RS232 and PROBE connectors, on the end of theIndicator III, must be kept clean. Allowing dirt to enterthe contacts can cause interference and keep themating connectors from plugging in or making propercontact.

During use, the PROBE connector is protected by theprobe cable connector. Leave the probe connectedduring storage so dirt does not enter.

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

Operating Instructions for168-7721Indicator IIIPlug the connector on the end of the 168-7722 or 4C-5485 Ultrasonic Probe Cable into the probe connectoron 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 a MACH(machine) display similar to those shown below.


MACH Display (Memory Clear)

3. The MACH number (in the upper left-hand cornerof the display) will be the one in use when theinstrument was last turned OFF. If internal memoryfor the machine number shown is clear (containsno stored information), it will appear as the MACHdisplay, as shown in Step 2.


MACH Display (Last Machine Used)

4. The example in Step 3, shows the MACH displaywith the model and serial (product identification)number of the last machine used shown.

The MACH(ine) number may be selected with theup arrow or down arrow keys.

Note: If the MACH(ine) number will not change: Pressthe “LOC/MACH” key to get to the MACH display asshown above. Then use the up arrow or down arrowkeys again.

14

Calibrating the Indicator III 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 question toensure the readings taken will be accurate.

Once the Indicator III and probe are calibrated withthis procedure, it will ONLY be accurate for measuringundercarriage steel or steel of a similar type.

If other materials are measured, the velocity must bechanged and a different PROBE CAL value used.Refer to the Section “Ultrasonic Velocity Adjustment”in this manual.


Applying Couplant To Ultrasonic Probe


Ultrasonic Wear Indicator III And Probe Being Calibrated

A metal calibration disk, Figure 21, is used to checkthe accuracy and calibrate the Indicator III and probe.

1. Place a small amount of 9U-7981Couplant onthe sensing end of the probe. See Figure 20.

2. Press the probe against the metal calibration diskon the top of the Indicator III. See Figure 21.

3. A number will appear at the MEASURED VALUEdisplay. 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 OFFusing the Settings menu) to indicate goodcoupling.


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 beepingsound 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 asshown in Step 3, follow the instructions in Step 6.

15


Probe Removed From Calibration Disk

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

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


PROBE CAL Key Pressed

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


Calibration Complete

8. The MEASURED VALUE, shown in Step 7, shouldnow be correct. If not, repeat this procedure untilcorrect.

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

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

UndercarriageMeasurement Procedure

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

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

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

Clearing The Memory

1. If a (CLEAR) machine cannot be located, any oneor all machines can be cleared by first pressingand releasing the red SHIFT key and then pressingCLR MACH key.


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


Display While One Machine Is Being Cleared

3. The message shown above will appear on thedisplay for a short time. The (CLEAR) messageindicates the memory has been cleared and isready for a new data.

4. To clear all machines, first press the up or downarrow key to move the cursor to the bottom line ofthe display, which shows CLR ALL MACH. Pressthe VALUE key.

16


Display While All Machines Are Being Cleared

5. The display will then be replaced with the (CLEAR)message indicating the memory has been clearedand is ready for new data.

Using LOC(ation)Mode of Operation

To store ultrasonic measurements and inputinformation about the machine being measured, theIndicator III must be in the LOC(ation) modeoperation.

To change to the LOC(ation) mode from the MACH(ine) mode, press the LOC/MACH key. This keyalways changes the display to the other mode ofoperation. If the word MACH is not on the display, theIndicator III is in the LOC(ation) mode.

Once in the LOC(ation) mode, the 71 differentundercarriage storage locations shown in Table 5,“List of Undercarriage Storage LOC(ation) Displays”are available for use. These storage locations can beaccessed with the up and down arrow keys. Refer tothe Section “UndercarriageMeasurement DisplayMap” in this manual for additional information on howto change between the various displays.

List of Undercarriage Storage LOC(ation) Displays

Table 5

Loc. Display Notes

1 MODEL The machine model number

2 SERIALNUMBER

The machine serial number

3 DATE MM/DD/YYYYDATE DD/MM/YYYY

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

4 HOURS The service hour meter reading on themachine

5 HRS/WEEK The number of hours the machine hasworked per week

6 MILESKM

The reading on the machines odome-ter in miles or kilometers

7 MILES/WEEKKM/WEEK

The distance the machine has trav-eled per week

8 JOB SITE The location of the machine

(continued)

(Table 5, contd)

9 IMPACT COND The underfoot Conditions - Impact,use SET DIGIT: MODERATE, HIGH,LOW

10 ABRASIVECOND

The underfoot Conditions - Abrasive,use SET DIGIT: MODERATE, HIGH,LOW

11 MOISTURECOND

The underfoot Conditions - Moisture,use SET DIGIT: MODERATE, HIGH,LOW

11 PACKING COND The underfoot Conditions - Packing,use SET DIGIT: MODERATE, HIGH,LOW

13 BUSHINGALLOW

Bushing allowable wear, use SETDIGIT: GREATER, LESSER

14 LTRACK 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 - SETDIGIT

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, DEPTHGAUGE

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

23 F IDLER SONIC Front idler ultrasonic measurement -use SET DIGIT

24 R IDLER DEPTH Rear idler depth gauge meas.

25 R IDLER SONIC Rear idler ultrasonic measurement

26 L CAR. ROLL 1 Left carrier roller number 1



29 CAR. ROLLTOOL

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

30 L ROLLER 1 Left track roller number 1










(continued)

17

(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 SETDIGIT

46 A BUSHING EXT Right bushing external wear

47 R SHOE Right shoe measurement

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

49 F IDLER SONIC Front idler ultrasonic measurement

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

51 R IDLER SONIC Rear idler ultrasonic measurement

52 A CAR. ROLL 1 Right carrier roller number 1



55 A ROLLER 1 Right track roller number 1










65 R SPROCKET Right sprocket - use SET DIGIT

66 NOTES LINE 1 16 characters - use SET DIGIT




70 SPARE # 1 For extra measurement

71 SPARE # 2 For extra measurement

Note: The Setting Menu is used to change how theDate (location 3), the Distance (location 6), and theDistance per Week (location 7) are displayed.


MODEL Display With Empty MODEL Number


MODEL Display ContainingMODEL Number

The first storage location is MODEL. This display isshown above in the way it appears with and without amodel number in memory. The machine modelnumber can be entered where the dotted line is or anumber already shown can be changed. This displaywill always be the first display shown when switchingfrom the MACH(ine) or LOC(ation) mode of operation.

Entering Information into the Indicator III

If the memory contains a MODEL number, the modelnumber will always be shown on the display. Ifmemory does not contain a MODEL number, dashedlines will show where the model number should beentered.

To enter the MODEL, press the VALUE key and thefirst number digit location will become a blinking box.Whenever a blinking box is on the display, numbers oralphabetical characters may be entered directly usingthe keys on the front panel.

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

To enter a blue character, the blue SHIFT key must bepressed and released before the character key ispressed.

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 is theSERIAL NUMBER.

18

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

Up to 16 numbers or letters in any combination can beentered as the serial number on the blanks provided.If the serial number does not fill all the blanks, theserial number will be moved to the right of the displaywhen saved.

The same procedure will be used for entering:

• DATE

• HOURS

• HRS. PER WEEK

• MILES or KM

• MILES PERWEEK or KM PERWEEK

• JOB SITE, and

Changing Displays with Words

The 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 IMPACTWith AlternateWord MODERATE


Example Of IMPACTWith AlternateWord HIGH


Example Of IMPACTWith Alternate word LOW

On these displays, alternate words are available. Toview the other words available, press the VALUE key.The other words will appear, as shown in the previousexamples.

To select and store the desired word in the memory,leave in the display and press the up arrow key tomove on to the next location. The selected word willalways reappear in the display when that display isused again.

Measuring Track Sag

The first display for a measurement is L TRACK SAG(left track sag). This measurement cannot be takenwith the Indicator III.The measurement must be takenaccording to the instructions in the CTS handbookwith a tape measure and manually entered into the IIImemory.

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. Refer tothe Section “Entering Information into the IndicatorIII”.

3. When the proper number has been entered, pressthe SAVE key to continue with the next reading.

Taking UltrasonicMeasurements

The next LOC(ation) is L LINK (left link measurement)and is the first measurement to be taken with theultrasonic probe.

Note: Refer to the Section “UndercarriageMeasurement Techniques”, in this manual, for detailson how to measure each undercarriage component.

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

2. The measurement will appear on the display aboveMEASURED 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 (4.92 IN) flashwhile the probe is coupled and the beeping soundoccurs 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 the MACH(ine) Display Mode or in LOC(ation) Display Modesscreen that accepts ultrasonic measurements.

19

Saving Measured Values in Memory

The measured value shown on the display can besaved in the memory of the wear indicator by pressingthe “SAVE” key. After a (SAVE) indication hasflashed on the display, the next undercarriage part tobe measured will automatically appear on the display.

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

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

Tool Displays

Some displays refer to the type of tool used formeasurement of the component described. If a toolother than the ultrasonic is used to measure thecomponent, the correct tool must be selected. This isneeded to indicate which wear charts should be used.An example is the BUSHING TOOL display as shownbelow:


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: DEPTHGAUGE

Pressing the VALUE key will select CALIPER orDEPTH GAUGE. Select the tool to be used and thenpress the up arrow key to move to the next displayand the selected tool will be put in memory.

Continue through the LOCATION displays until all ofthe undercarriagemeasurements have been takenand recorded.

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

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

Measurement Operating Tips

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

1. The sequence of the undercarriage storagelocations were selected to transfer into the CustomTrack Service personal computer program. Untilyou have this program, it may save time to enterand save only the serial number andmeasurements in the indicator III. Then manuallyrecord the data for locations 2 through 13 directlyon the CTS Form. Refer to the Section “GeneralInformation”. After taking measurements, scrollthrough the stored measurements while manuallyrecording them on the CTS form.

2. When using the arrow keys, press and release thekeys to change the display slowly, or hold the keydown to scroll rapidly.

3. For users preferring not to use the memory feature,ultrasonic measurements can be taken at any timeregardless of the LOC(ation) or MACH(ine)settings. When taking measurements, the9U-7981Couplant must be applied to the sensingend of the probe before measuring component.

4. To couple the ultrasonic probe to a component, it isimportant to have the 9U-7981Couplant betweenthe sensing end of the probe and the component.The probe tip surface must be flat (square) with thepart being measured. It may be easier to hold theprobe properly if a finger is held on top of theprobe.

5. When taking ultrasonic measurements, keep inmind the first reading displayed may not be thebest measurement. Always move the probe aroundthe part surface to find the smallest, or most wornmeasurement.

6. Saving ultrasonic measurements can be doneeither while holding the probe on the part or afterremoving the probe. If you prefer to remove theprobe before pressing “SAVE” , pull off the probequickly to prevent the measurement fromincreasing slightly as the probe is removed.

20

UndercarriageMeasurementTechniques

Track Links


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 and takethe smallest reading.

Track Shoes


Probe Located On The BottomOf The Plate

1. Measure the distance from the bottom of the plateto tip of the grouser.


Probe Located On The Tip Of The Grouser

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, do notmeasure the rear grouser due to interference withthe trailing edge.

4. On regrousered shoes, it may be necessary to usea depth gauge or take ultrasonic measurementsfrom the tip and the bottom of the plate and add thereadings together, since the weld does notcompletely penetrate.

Track Bushing


1. Measure the wall thickness.

2. Slowly slide the probe around the reverse driveside to find the smallest dimension and save thismeasurement.

3. Next, slide the probe around the vertical andforward drive sides to check if the measurement issmaller (indicating more worn). Always save thesmallest measurement.

21

Idler


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 wear onthe tread surface.

3. Add center flange wear to the depth gauge,measurement before determining percent worn.

Carrier Roller

Three Piece Rims


Measure the Thickness Of Press-On Rim



Measure Distance From The Outside Of Tread Surface To The Bore

Note: Due to the use of tapered roller bearings, morethan one thickness can be found along each treadsurface.

It is important to place the probe on the outer half ofthe tread surface on the side of the roller opposite theshaft.

Note: The Ultrasonic Wear Indicator III will notmeasure cast iron rollers. Some D3, D4, D5, and D6Tractors or 225 Excavator carrier rollers are cast iron.

22

Track Roller


1. Measure the distance from the tread surface to thebore.

2. Do not measure to the retainer bolt holes on H, N,and L series Track-Type Tractors and currentTrack-Type Loaders. Observe the location of theretainer bolts and place the probe between them.On low sprocket Track-Type Tractors, earlier TypeLoaders, and Excavators the retainer bolts are notvisible. Observe the thickness measured valueclosely from roller to catch any abnormally smallthickness which would indicate a reading to thebolt hole.

3. On track rollers with noticeable cusp wear, slidethe probe along the cusp to get the smallestreadings. To speed the process, select the cuspthat normally is most worn (the cusp closer to thecenter of the roller), rather than sliding the probeover both cusps each time.

Competitive Parts

Do not measure competitive undercarriages with theindicator III. The internal dimensions of these parts willlikely be different than on the Cat designed parts,resulting in incorrect percent worn readings.

Measuring the Thickness of Parts Otherthan Undercarriage

In addition to measuring undercarriage wear, theUltrasonic Wear Indicator III can be used to measuresteel part thickness without changing any settings.This is simple to do because the wear indicator isdesigned to show the MEASURED VALUE regardlessof which keys have been pressed. This allows a non-experienced person to take readings.

Examples where this may be used to check the wallthickness of a:

• Bulldozer blade

• Bucket base edge

• Scraper bowl

Note: In addition to measuring steel parts, many othermaterials can be measured. However, to accuratelymeasure these materials, the velocity setting of theIndicator III must be changed. Refer to the Section“Ultrasonic Velocity Adjustment” in this manual forcomplete information other than steel.

1. Install 168-7722 or 4C-5485 Probe, and calibratethe Indicator III and probe. Refer to the Section“Ultrasonic Velocity Adjustment” in this manual.When taking measurements, the 9U-7981Couplant must be applied to the sensing end of theprobe 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 be measured.The thickness of the material will be shown atMEASURED VALUE on the display. Whenever theprobe is properly coupled, either IN or MM willshow on the display. Also, a steady beeping soundwill be heard (if not turned OFF in the SettingsMenu). When the probe is removed from thematerial, the last reading will remain on the display.

3. To check the accuracy of the reading, measure apiece of the same type of material of knownthickness. If the reading is not correct, the velocitymay be adjusted to make the Indicator III readaccurate. Refer to the Section “Ultrasonic VelocityAdjustment” in this manual.

Transferring the Memory Values Toor From a ComputerThe information contained (saved) in the Indicator IIImemory may be transferred to an IBM or compatiblepersonal computer for storage or printing using theCustom Track Service (CTS) personal computerprogram.

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 the PC.The CLR ALL MACH function may be used tomanually clear all 64 machines.

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

Note:One exception is if there is no MACH(ine) datastored in the Indicator III before the transfer, then atransfer from the PC to the Indicator III will result in thenew machine data being stored beginning with theMachine No. 1 instead of the MACH(ine) No. currentlyshown on the screen.

23

Note:When transferringmachine data from a PC tothe Indicator III, the Indicator III does not wrap aroundthe 64 MACH(ine) locations. The data from threemachines is transferred from the PC, MACH(ine)memory in the Indicator III is not empty, and theIndicator III displays MACH(ine) 63. The first machinetransferred will be stored in MACH(ine) 63, the secondmachine transferred will be stored in MACH(ine) 64,and the third machine will overwrite the secondmachine and be stored n MACH(ine) 64.

24

SettingsMenu

Illustration 46

25

g02902257

Settings Menu Operation (Default States Shown)

26


Settings Menu Operation

27

The 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 as Figure 46.The Settings Menu contains these functions in thisorder: Resolution, Turnoff, Velocity, Serial, Beeper,Language, Distance, and Date. Resolution is the firstfunction displayed when entering the Settings Menu.Press the up down arrow to scroll forward through theSettings Menu or up arrow to scroll backwardsthrough the Settings Menu. Figure 47 shows thedifferent settings that can be selected with eachfunction in the Settings Menu.

Resolution

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

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

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

Turnoff

This function allows for longer battery life byautomatically turning the Indicator III OFF if it has notbeen used for 5 minutes. Normal operation of the keypad ON/OFF switch is not affected.

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

2. AUTO (default position) - Indicator III automaticallyturns off after 5 minutes and no keys have beenpressed or the probe has not been coupled. TheIndicator III will also turn off by using the “ON/OFF”key switch.

Velocity

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

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

2. ON - Velocity adjust enabled.

Serial

This function controls the speed (BAUD Rate) of theRS232 communications signal of transferringmemoryvalues from the 168-7721Ultrasonic Wear IndicatorIII to a personal computer with Custom Track Servicesoftware program installed or transferring the memoryvalues back to the Indicator III. The different BAUDrates that are available are:

1. 1200.

2. 9600 (default position).

3. 19200.

Beeper

This function turns ON or OFF the beeper that soundswhen the probe is properly coupled to the materialbeing measured. When turned OFF, coupling will stillbe indicated any MM or IN being displayed beside theMEASURED VALUE when properly coupled.

1. ON (default position).

2. OFF.

Language

This function allows the language to be changed. Allof these languages are in the 168-7721UltrasonicWear Indicator III and are selectable.

1. ENGLISH (default position).

2. FRENCH.

3. GERMAN.

4. PORTUGUESE.

5. SPANISH.

Distance

Allows the units for distance to be changed:

1. MILES (default position).

2. KM - Kilometers.

Date

This function allows date configuration to be selected:

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

2. DD/MM/YYYY - Day, Month, and Year.

Ultrasonic Velocity AdjustmentAdjustment of the velocity calibrates the Indicator IIIso it can be used accurately to measure the thicknessof materials other than undercarriage steel.

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

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

28

Table 6

Material VelocityMM/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)

Glass 5.33 mm(0.210 inch)

5.6 mm (0.22 inch)

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)

UndercarriageSteel

5.87 mm(0.231 inch)

6.3 mm (0.25 inch)

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

Checking the Ultrasonic Velocity

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

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

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


Example of Screen Display with VEL in MM/uSEC


Example of Screen Display with VEL in IN/uSEC

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

If the number is not correct, or you plan to measureother materials, the velocity number can bechanged. Refer to the Section “Changing theUltrasonic Velocity”.

Changing the Ultrasonic Velocity

1. Locate the velocity number for the material to bemeasured in Table 6. The numbers given in Table 6are approximate, and slightly different numbersmay need to be used to give accurate readingsbecause of differences in material composition.

2. With the display showing the velocity, as shown inStep 2 in “Checking the Ultrasonic Velocity”, pressthe VALUE key. The first digit of the velocitynumber will flash. Use the number keys to set thevelocity to the desired number

3. When the desired velocity number is shown on thedisplay, press the SAVE key and the Indicator IIIwill 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 end ofthe probe, on the calibration disk. The numbershown as the MEASURED VALUE on the displayshould be the value shown on the Velocity Tableunder PROBE CAL. MEASURED VALUE for thenew material. Every time the calibration disk ismeasured with this new velocity setting, thisreading should appear on the MEASURED VALUEdisplay instead of 6.3 mm (0.25 inch).

5. Measure a known thickness of the new materialwith the Indicator III to be sure that the readingsare accurate.

6. If the readings are not exact, change the velocitysetting number right-hand digit by one andrecalibrate.

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

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Battery Level Monitor

A Battery Level Monitor displays the estimated batterypower remaining. Since many factors influence thedischarge rate, the battery level monitor is only anestimate of the remaining battery life and should onlybe used as an estimate. The Battery Level Monitor willshow a percent value ranging from 0% to 100% in10% increments. Monitor shows 100% when thebattery voltage is greater than or equal to 6.0 V. Avalue of 0% will be displayed anytime the batteryvoltage falls to 5.4 V or less. The Battery LevelMonitor screen will appear as follows:


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

Low Battery Indication

The LCD display will flash for at least 30 secondswhen the battery voltage reaches 6.14 V, which iswhen a minimum of 2 hours of battery life is left. It willthen stop flashing for about 30 minutes and return toat least a 30 second flashing period. When theIndicator III has reached a minimum of 1 hour ofremaining battery life, the display will flash andcontinue to flash until the power is increased bycharging the NiCad batteries or installing new alkalinebatteries. The Indicator III shuts down when thebattery voltage reaches approximately 5.12 V.

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

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

Return to Last Menu Screen

The Indicator III will remember the last MACH(ine) orLOC(ation) Display Mode screen that was displayedwhen the Indicator III was last turned OFF. If theIndicator III was turned OFF in the Settings Menu orshowing the Battery Level Monitor screen, then it willdisplay the last MACH(ine) or LOC(ation) DisplayMode screen when the Indicator III was last poweredup. The Machine or Location Display Mode screen willnot be remembered if a factory reset was performedor if the Indicator III was abnormally powered down.For example, by pulling out batteries while theIndicator III is ON.

Factory Reset

This 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 the default states.To reset, the Indicator III must be OFF. Then, pressand hold the “CLR” and “ON/OFF” keys at the sametime for at least 3 seconds. The Indicator III will turnON and will display “"FACTORY RESET” while thefactory reset is being performed.

Viewing the Software Version Screen

The 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 press“ON/OFF” to turn the Indicator III ON.


Example of Screen Display For SOFTWARE VERSION Number

3. When the Indicator III comes ON, the SoftwareVersion screen is displayed, as shown in Step 2.To leave this screen, turn the Indicator III OFF. Thesoftware is the program that operates themicroprocessor in the Indicator III. It is containednonvolatile, located in the Indicator III, so removingthe batteries for an indefinite time will not affect thememory.

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Checking the Operation of the Indicator III

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

Perform all the procedures, as shown in the Section“Operating Instructions for 168-7721Indicator III”, inthis manual.

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

Alternate Method

An alternate method is to measure a known thicknessof undercarriage steel.

1. Check the display of the undercarriage storagelocations for one machine. During this test, use allfront panel keys to be sure that the panel keysoperate correctly.

If the Indicator III does not operate properly duringthis test, refer to the Section “Troubleshooting” inthis manual.

2. Next, test the Indicator III on actual undercarriagecomponents. Correct measurements shouldappear on the MEASURED VALUE display withouthaving to move the probe back and forth.

3. Also check to see that measurements can betaken on thick undercarriage components such asthrough track shoe grouser bars.

4. If the Indicator III has trouble making any of thesereadings, the gain may need to be adjusted. Referto the Section “Troubleshooting” in this manual forthe procedures to adjust the gain.

5. This completes the test of the Indicator III.

Adjusting the Display Contrast

The display contrast may be adjusted to the userspreference. The contrast has been set at the factory. Ifthe contrast needs to be changed, use the followingprocedures:

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


Cover Removed To Access The Gain And Display Contrastadjustments(1) RP1 Gain Adjustment (2) RP2 Display Contrast Adjustment

2. Locate contrast adjustment, Figure 52 on the topof the printed circuit board. It is one of only twoscrewdriver adjustments and is located below thecalibration block and is labeled RP2 on the printedcircuit board.

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

4. To adjust the display contrast, use a small flat headscrewdriver to turn the contrast while viewing thedisplay screen. Continue to adjust until theinformation on the screen is clear to the userpreference. Once the setting is obtained, replacethe rear cover.

Adjusting the Gain

If the gain is out of adjustment, it will result ininaccurate or hard to get readings, or no echo. If thegain needs to be changed, use the followingprocedures:

Note: The gain adjustment is set at the factory usingprecision instruments and should not be changedunless necessary.

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

2. Locate gain adjustment, Figure 52, on the top ofthe printed circuit board.

31

3. Before turning this adjustment, check and see ifthe position is marked. If not marked, place a markon the small plastic case. This is the factory settingof the gain adjustment which was set usinginstruments. Marking this position will allow you toreturn to original setting if you have trouble with theoperation of the Indicator III during this procedure.

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

5. To adjust the gain, use a small flathead screwdriverto turn the gain adjustment while measuring a thickundercarriage component, such as a large trackroller or shoe grouser.

a. Turning the adjustment clockwise, right,decreases the gain until no echo is received.No beeping sound heard and no measurementtaken.

b. Turning the adjustment counterclockwise, left,increases the gain.

Note: If the gain is increased too much, the beeperwill not turn OFF when the probe is removed fromthe 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, first checkthe Battery Level Monitor to see if the batteries havesufficient power remaining. If not, and NiCad batteriesare installed, then recharge or replace with newalkaline batteries.

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

Note: The longest life will be obtained by charging thebatteries only after the display is flashing, indicatingthe batteries are fully or near being discharged.

If the Battery Level Monitor shows that the batterieshave sufficient power remaining and the Indicator IIIstill will not turn ON, it must be sent in for repair. Referto the Section “Service” in this manual.

If the display comes on but the Indicator III will nottake measurements, the problemmay be in the probe.

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

1. Take the Indicator III to a quiet place.

2. Put the probe close to your ear.

3. Turn the Indicator III ON.

4. You should hear a high frequency sound emittedby 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 the IndicatorIII. The cable connector will not fit completelyagainst the connector panel, but will still makecontact. Again, with the Indicator III ON, youshould hear the sound emitted by the probe. If youdo not hear the sound both times, the probe hasfailed and must be replaced.

6. Sometimes the crosstalk barrier (between the twohalves on the face of the probe) becomes worn orsaturated with couplant. This can result in badreadings or readings while not measuring anymaterial. If this problem occurs, try adjusting thegain of the Indicator III. If this fails to correct theproblem, replace the probe.

UndercarriageMeasurementDisplay MapNote: Settings menu in default states.

32


33

Location Display MapNote: Settings menu in default states and units areinches.

34


35


36

9U-7981CouplantMaterial SafetyData Sheet(To comply with 29 CFR 1910, 1200)

Effective Date: 2/98

N/A = not applicable or not available

Section 1 - Product Identification


Section 2 - Hazardous Ingredients


Section 3 - Physical Data (nominal)


Section 4 - Fire and Explosion Hazard Data


Section 5 - Reactivity Data


Section 6 - Health Hazard and First Aid Data


Section 7 - Storage and Handling Information

37


Section 8 - Control Measures


ServiceIf the Ultrasonic Wear Indicator III does not operatecorrectly, recharge or replace the internal NiCadbatteries with new ones and check the operation. If itstill does not operate, refer to the Section“Troubleshooting” in this manual. If the Indicator III isfound to be faulty, contact Dealer Service Tools forinformation on how to obtain the needed repairservice.

Dealer Service Tools provides the instrument userwith a warranty of 1 year from purchase date. If thereason for failure is determined to be abuse, thewarranty is declared void. Any out-of-warranty repairswill be charged to the owner.

■

©2013 CaterpillarAll Rights Reserved

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

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

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