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R

TOOL
OPERATING
MANUAL
168-7720 Ultrasonic Wear Indicator III Group
SMCS: 0787

NEHS0730-02
November 2005

Table of Contents

Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Three-Piece Rims . . . . . . . . . . . . . . . . . . . . . . 24
Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Competitive Parts . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring the Thickness of Parts Other than
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transferring the Memory Values to or From a
Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Turnoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Beeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ultrasonic Velocity Adjustment . . . . . . . . . . . . . . 30
Checking the Ultrasonic Velocity . . . . . . . . . . . 30
Changing the Ultrasonic Velocity . . . . . . . . . . . 30
Battery Level Monitor . . . . . . . . . . . . . . . . . . . . . 31
Low Battery Indication . . . . . . . . . . . . . . . . . . . . 31
Return to Last Menu Screen . . . . . . . . . . . . . . . . 31
Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Viewing the Software Version Screen . . . . . . . . . 31
Checking the Operation of the Indicator III . . . . 32
Alternate Method. . . . . . . . . . . . . . . . . . . . . . . . 32
Adjusting the Displays Contrast . . . . . . . . . . . . . 32
Adjusting the Gain. . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Undercarriage Measurement Display Map. . . . . 34
LOC(ation) Display Map . . . . . . . . . . . . . . . . . . . 35
9U-7981 Couplant Material Safety Data Sheet . . 37
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Other Uses for the Indicator III . . . . . . . . . . . . . . . 3
Benefits of the Ultrasonic Wear Indicator III . . . . . 3
Features of the Indicator III . . . . . . . . . . . . . . . . . 3
General Measurement Benefits. . . . . . . . . . . . . . 4
Undercarriage Measurement Benefits . . . . . . . . 4
168-7720 Ultrasonic Wear Indicator III Group . . . 5
Storage of Conventional Tools . . . . . . . . . . . . . . 5
Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
168-7720 Ultrasonic Wear Indicator III Group
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
168-7722 Ultrasonic Probe Specifications . . . . . . 7
156-1077 Power Inverter Specifications . . . . . . . . 8
Connections to the 168-7721 Indicator III . . . . . . 8
168-7721 Indicator III Description . . . . . . . . . . . . 9
Abbreviations and Descriptions . . . . . . . . . . . . . 9
Description of Displays and Keys. . . . . . . . . . . . 9
Charging the Internal NiCad (rechargeable)
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing the Internal Rechargeable
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connecting to DC Power. . . . . . . . . . . . . . . . . . 14
Care and Cleaning of 168-7721 Indicator III . . . 15
Removing the 9U-7981 Couplant Residue . . . . 15
Cleaning the Case and Front Panel Key Pad . . 15
Care of Connectors . . . . . . . . . . . . . . . . . . . . . . 15
Operating Instructions for 168-7721
Indicator III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Turn the Indicator III ON . . . . . . . . . . . . . . . . . . 16
Calibrating the Indicator III and Probe . . . . . . . 16
Undercarriage Measurement Procedure . . . . . 18
Clearing the Memory. . . . . . . . . . . . . . . . . . . . . 18
Using the LOC(ation) Mode of Operation . . . . . 18
List of Undercarriage Storage LOC(ation)
Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Entering Information into the Indicator III . . . . . 20
Changing Displays with Words . . . . . . . . . . . . . 20
Measuring Track Sag . . . . . . . . . . . . . . . . . . . . 21
Taking Ultrasonic Measurements . . . . . . . . . . . 21
Saving Measured Values in Memory. . . . . . . . . 21
Tool Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Measurement Operating Tips . . . . . . . . . . . . . . 22
Undercarriage Measurement Techniques. . . . . . 23
Track Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Track Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Track Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Introduction

Other Uses for the Indicator III


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

Benefits of the Ultrasonic


Wear Indicator III

Illustration 1. 168-7721 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.

The 168-7720 Ultrasonic Wear Indicator III Group


provides a new, fast, and accurate method of
measuring track-type machine undercarriage wear.

Features of the Indicator III


New design uses state-of-the-art surface mount
electronics for high reliability.

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.

Easy battery access - loosen the two battery


cover screws on the back of the Indicator III.
Backlit Liquid Crystal Display can be turned
ON or OFF.
Power Level Monitor shows estimated battery
power remaining in percent.

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.

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.)

The Ultrasonic Wear Indicator III measures the


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

168-7720 Ultrasonic Indicator III Group includes


an updated probe with a longer, more durable
cable.
Used with Custom Track Service (CTS)
inspections, which can be downloaded directly
to a computer for viewing or printing.
Uses five Alkaline or Nicad AA batteries
(no battery pack).

When taking measurements, the 9U-7981 Couplant


must be applied to the sensing end of the probe
before measuring. This allows the sound to be
transferred into the part being measured. For
convenience, the couplant container attaches to
the side of the Indicator III.

Automatically recalls and shows last machine or


location display screen used when turned ON.
When transferring machine data from a PC to the
Indicator III, the user can select where the data
will be stored.

General Measurement Benefits

Undercarriage Measurement
Benefits

Higher accuracy measurements. Digital display


of thickness is accurate to 0.1 mm (.01 in) for low
resolution mode, and 0.01 mm (.001 in) for high
resolution mode.

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.

Time savings in measuring undercarriage due to


reduced cleaning and measurement storage.

Measures track idler center flange thickness.

Easy to use. Thickness reading will always


appear on the display when the probe is used,
regardless of mode of operation.

Eliminates errors caused by dirt packed around


parts.
Accurately measures bushing wear after turning.

Calibrated for undercarriage steel, but velocity


can be adjusted to accurately measure other
materials such as aluminum, plastic, and glass.

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.

Reads thickness of parts where opposite side is


not accessible, such as a bulldozer blade,
bucket base edge, or scraper bowl thickness.
No writing. Stores readings in memory, then
transfers to a computer for printing.

Prompts CTS inspector on next reading location.

168-7720 Ultrasonic Wear


Indicator III Group

Storage Of Conventional Tools

Illustration 3. Storage For Conventional CTS Tools In


6V-7145 Carrying Case.
Refer to Chart B for item identification.

Illustration 2. 168-7721 Ultrasonic Wear Indicator III Group.


Refer to Chart A for item identification.

Chart B.
Storage Locations

Chart A.
168-7721 Ultrasonic Wear Indicator III
Item

Part No.

168-7721

168-7722

PEKP9400

Custom Track Service Handbook: Fits


under Indicator III

5P-3277

Ultrasonic Probe
(Declaration of Conformity not shown)

Tape Measure: 3 mm (10 ft) for pitch, sag,


and sprocket measurement

8H-8580

Scraper: For cleaning undercarriage


components

5P-8616

Sprocket Gauge: For D4, D5, and D6


Track-type Tractors

5P-8617

Sprocket Gauge: For D7, D8, and D9


Track-type Tractors

6V-9410

Depth Gauge: For measuring idlers

5P-3920

Steel Rule: 300 mm (12 in), store on top


of 9U-6000 Paper Towels

9U-7981

Couplant

6V-7145

Carrying Case

4C-4772

Foam Insert

4C-3024

Battery Charger (110/220 Volts AC,


50/60 Hz)

NEHS0730

Description

Description

NEEG2835

Part No.

Ultrasonic Wear Indicator III


(Calibration Certificate not shown)

Item

Paper Towels (16 sheets from 9U-6000


Paper Towel Case)
168-7720 Group Label (located in lid of
carrying case)
Four 1-9/16 inch protective caps for
RS232 connector

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.

Ultrasonic Wear Indicator III Group Tool


Operating Manual

NOTE: The part numbers for other conventional


undercarriage tools can be found in the CTS
Handbook.

Optional Items
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 4. Optional Items For 168-7721.

Chart C.
Optional Items
Item

Part No.

Description

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).

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).

4C-5897

Cable Assembly RS232 (Modem Cable):


For connecting the 168-7721 to a modem
which transfers data over telephone lines
to a personal computer.

1U-7445

NiCad (Nickel Cadmium) Rechargeable


Battery: (size AA) 1 per package.

1U-9533

Alkaline Battery: Non-rechargeable


battery (size AA) 96 per package.

156-1077

Power Inverter: For powering the 1687721 from 12VDC and includes battery
cables and a cigarette lighter.

9U-6175

Soft Protective Case: For protecting the


168-7721 during use.

Custom Track Service (CTS) software


program for transferring stored
measurements from the 168-7721 to an
IBM PC, or compatible, computer for
storage or printing. Also required when a
modem is used.

Additional Service Replacement Part (not


shown).

4C-5490

Couplant Holder: The service


replacement for the holder that stores the
9U-7981 Couplant container.

Illustration 5. 168-7721 Indicator III With 168-7722 Probe


Installed In 9U-6175 Soft Protective Case.

NOTE: Five batteries are required to power the


168-7721 Ultrasonic Wear Indicator III.
6

168-7720 Ultrasonic Wear


Indicator III Group
Specifications

Storage Temperature:
Without Batteries Installed . . . . . . . . -40C to 60C
(-40F to 140F)
With Alkaline Batteries Installed . . . -40C to 50C
(less than 6 months)
(-40F to 125F)

Power Supplied By 5 NiCad (Nickel Cadmium),


rechargeable batteries
(size AA) or non-rechargeable
1U-9533 Alkaline Batteries.

With NiCad Batteries Installed . . . . -20C to 45C


(less than 6 months)
(-4F to 113F)

NOTE: The five AA batteries are accessed by


removing the Indicator IIIs back cover. See
Replacing the Internal Rechargeable Batteries
section for the procedure.

Memory Size:
Flash Memory . . . . . . . . . . . . . . . . . . 32,768 Bytes
Random Access Memory (RAM) . . . . . 1024 Bytes
Electrically Erasable Memory . . . . . . 49,830 Bytes
RS232 Specifications . . . . 1200, 9600 (default), or
19,200 Baud rate

NOTICE

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

DO NOT attempt to recharge alkaline batteries


using the 4C-3024 Battery Charger.

External Dimensions:
6V-7145 Carrying Case . . . . 432 x 390 x 114 mm
(17 x 15.4 x 4.5 in)

Attempting to charge an alkaline battery can


result in damage to the 168-7721 Ultrasonic
Wear Indicator III.

168-7721 Indicator III . . . . . . . 190 x 168 x 40 mm


(7.5 x 6.6 x 1.6 in)

Place a piece of tape over the charge connector,


to prevent charging, when using alkaline
batteries.

Weight:
168-7720 Group . . . . . . . . . . . . . . . . 3 kg (6.75 lb)
168-7721 Indicator III . . . . . . . . . . . 0.9 kg (2.0 lb)
168-7722 Probe . . . . . . . . . . . . . . 0.113 kg (.25 lb)

Approximate Battery Life (with Indicator IIIs


backlight OFF and beeper ON).
NiCad Rechargeable . . . . . . . . . . . . . . . 19 Hours
Alkaline Non-rechargeable . . . . . . . . . . . 47 Hours

168-7722 Ultrasonic Probe


Specifications

Approximate Battery Life (with Indicator IIIs


backlight and beeper ON).
NiCad Rechargeable . . . . . . . . . . . . . . . 14 Hours
Alkaline Non-rechargeable . . . . . . . . . . . 34 Hours

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


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

Indicator III shuts down . . . . . . . . . . . . . .5.12 volts


Power Line Operation:
4C-3024 Battery Charger . . . 110 or 220 Volts AC,
50/60 Hz.

Allowable Surface Temperature . . -18C to 150C


(0F to 300F)
Cable Length . . . . . . . . . . . . . . . . 1524 mm (60 in)

Measurement Range (Steel) . . . 1.27 mm (.050 in)


to 254 mm (10.0 in)

Includes Certificate of Conformity

Measuring Resolution:
Low Resolution (default) . . . . . 0.1 mm or (.01 in)
High Resolution . . . . . . . . . . 0.01 mm or (.001 in)
Measurement Accuracy:
Low Resolution (default) . . . . 0.1 mm or (0.01 in)
High Resolution . . . . . . . . 0.076 mm or (.003 in)
Operating Temperature . . . . . . . . . . -18C to 60C
(OF to 140F)

156-1077 Power Inverter


Specifications

Chart D.
Connectors For 168-7721 Indicator III
Item

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


Input Voltage Protection . . . . . Automatically shuts
down if voltage exceeds 15 VDC
(the inverter will be damaged if it is
connected to a 24 VDC battery)
Low Battery Indicator . . . . . . . . . . . . Audible alarm
sounds if input voltage drops to 10.6 VDC

Part No.

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.

4C-5490

Holder
Used to hold the 9U-7981 Couplant
Dispenser

RS232

Probe

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


Operating Temperature Range . . . . 10C to 26.7C
(50F to 80F)
Over Temperature Protection . . . . When the power
inverters internal heat sinks reach 65.5C (150F),
the inverter will automatically shut down. The
inverter may be restarted by first disconnecting
the inverter and allowing it to cool for 15 minutes
before reconnecting.
No Load Current Draw . . . . Less than 0.2 Ampere
Output Receptacle . . . . . . . . . . . . . . Dual 3-prong
Fuse . . . . . . . . . . . . . . . . . . . 35 Amp (spade type)
Weight . . . . . . . . . . . . . . . . . . . . . . 1.6 Kg (3.5 Ibs)
Dimensions . . . . . . . . . . . . . . . 155 x 127 x 58 mm
(6.1 x 5.0 x 2.3 in)
Maximum Continuous Power . . . . . . . . . 300 Watts
Surge Capability (Peak Power) . . . . . . . . 600 Watts
Overload Protection . . . . . . . Inverter automatically
shuts down if continuous power
is greater than 300 Watts

Connections to the 168-7721


Indicator III

Illustration 6. Connectors For 168-7721.


Refer to Chart C for item identification.
8

Description

Steel Calibration Disk


The disk is used to check the accuracy of
the wear indicator and recalibrate the
wear indicator, if necessary. For
additional information, refer to Calibrating
the Ultrasonic Wear Indicator III in this
manual.
Connector (shown without 1 9/16
protective cap installed)
Used to connect
4C-5488 Cable As. RS232 (PC AT) or
4C-5489 Cable As. RS232 (PC XT) or
4C-5897 Cable As. RS232 (Modem Cable)
These cables can be used to transfer
stored undercarriage data from the
168-7721 to a personal computer or
printer. Refer to Optional Items in this
manual, for each cables specific function
and software program requirements.
Charger Connector
Used to connect the Battery Charger
when recharging the rechargeable
Batteries (NiCad). Also used to power the
168-7721 with the 4C-3024 Battery
Charger. The plug of the 4C-4032 can be
plugged into the 156-1077 Power Inverter
to provide 12 VDC power for powering the
indicator.
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.

168-7721 Indicator III


Description

4. CHARGE:
Identifies the connector, located on top panel,
for the 4C-3024 Battery Charger.
5. PROBE:
Identifies the connector, located on the top
panel, for the 168-7722 or 4C-5485 Ultrasonic
Probe.
6. LOCATION & LOC:
Location, referred to as LOC(ation) in this
manual. Refers to undercarriage data locations.

Description of Displays and Keys


7. MACH(ine) DISPLAY:
Identifies the machine number (from 1 to 64)
corresponding to the information on the display.
When data is saved, it can be located later by
going to this machine number.
8. LOCATION Display:
Shows the undercarriage storage LOC(ation)
display selected by the up or down arrow keys
and shows the machine model when in the
MACH(ine) mode of operation.
The display, in Illustration 7, is in the LOC(ation)
mode.
9. MEASURED VALUE:
Displays the thickness value being measured or
the value of the last measurement taken.
MM or IN will appear to the right of the value
displayed, when measuring, to show the probe
is properly coupled to the material.

Illustration 7. Indicator III Front Panel And Key Pad.

Abbreviations and Descriptions


Used on Front Panel and Key Pad

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.

1. MACH:
Machine, referred to as MACH(ine) in this
manual.
2. 6.3 mm (.25 in):
Describes the metal calibration disks thickness
measured in millimeters and inches during
probe calibration (metal calibration disk is
located on top panel).
3. RS232:
Identifies connector located on top panel which
provides the RS232 signal connection, for the
optional cables, for transferring data to a
personal computer. Refer to Optional Items
(in this manual) for each cables specific
function, software program requirements, and
use with the 168-7721 Indicator III.

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

15. CLR/CLR MACH:


This key will provide one of two functions:

SAVE:
Press to store the MEASURED VALUE in the
MEMORY VALUE location. After the value is
saved, the display will automatically advance
to the next LOCATION.

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.

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

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.

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

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.

13. PROBE CAL:


Calibrates the ultrasonic probe so the Indicator
III will read accurately.
To use, apply couplant to the sensing end of
the probe and press probe to the metal
calibration disk on top of the Indicator III.

Use the up or down arrow keys to move to any


of the 64 machine storage locations.

If the MEASURED VALUE display is not 6.3 mm


or (.25 in) while in the Low Resolution mode,
press PROBE CAL while holding the probe on
the disk and it should read correctly.

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 the MEASURED VALUE display is not in the


range of 6.25 to 6.32 mm or (.246 to .249 in)
while in the High Resolution mode, press
PROBE CAL while holding the probe on the
disk and it should read correctly.

Use the up or down arrow keys to move to any


of the individual measurement locations for the
MACH(ine) number shown in the upper left of
the display.
17. Left Arrow, A or B:
This key will provide one of two functions:

Refer to Calibrating the Ultrasonic Wear


Indicator III and Checking the Ultrasonic
Velocity in this manual.

In the LOC(ation) mode, the flashing cursor is


moved one position to the left for each key
press.

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

When preceded by pressing either the red or


blue SHIFT key, the corresponding colored
character is entered on the display.

Indicator III will automatically turn OFF after 5


minutes if not in use. This function can be
disabled in the Settings Menu. Refer to
Settings Menu in this manual.

10

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:

18. UP ARROW / BACKLIGHT:


This key will provide one of two functions:
UP ARROW:
If LOCATION display reads MACH:
Press the up arrow key to advance to the next
MACH(ine) number. This is the MACH(ine)
mode of operation.

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.

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.

RIGHT ARROW:
Used to move the flashing cursor to the right
one character for each key press.

Hold the up arrow key to scroll in the


MACH(ine) or LOC(ation) Display Mode.
BACKLIGHT:
Press and release the blue SHIFT key, then
press this key to turn ON the displays
backlight. Perform the same keystrokes to turn
the backlight OFF.

NOTE: Pressing and holding this key will scroll the


flashing cursor at a faster rate.
21. SHIFT (blue):
Used to enter any blue character from the key
pad.

NOTE: When Ultrasonic Wear Indicator III is in


Manual Turnoff mode (selectable in the settings
menu): If backlight is ON, no key has been
pressed, and probe not coupled for 5 minutes, then
the backlight will turn OFF. The backlight will
automatically turn ON when a key is pressed or
probe is coupled.

22. SHIFT (red):


Used to enter any red character from the key
pad.
NOTE: The SHIFT keys are to be pressed and
released before pressing the desired character key.

19. DOWN ARROW:


Use to move the display in the opposite
direction as the up arrow.

23. Alphanumeric keys:


These keys are used to enter directly, into the
display, any information the user wishes to
enter into storage when in the LOC(ation)
mode.

NOTE: Arrow keys will change display once every


time pressed or may be held down to scroll
(change) the display at a faster rate.

11

Charging the Internal NiCad


(rechargeable) Batteries

NOTE: The Indicator III will not be damaged if the


charger is left on for longer time periods.
NOTE: For maximum battery life, recharge only
after the display flashes or goes blank, indicating
the batteries are near or fully discharged.

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).

Replacing the Internal


Rechargeable Batteries

The batteries must be charged before using the


168-7720 Ultrasonic Wear Indicator III Group.

The 168-7721 Ultrasonic Wear Indicator III is


supplied with five NiCad (Nickel Cadmium),
rechargeable batteries (size AA).
These can be replaced with new 1U-7445 Batteries
when they no longer give sufficient operating time,
or they can be replaced with 1U-9533 Alkaline
(non-rechargeable) Batteries.

NOTE: The internal batteries can be removed


indefinitely and the internal memory values will not
be affected.

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

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

Procedure

Attempting to charge an alkaline battery can


result in damage to the 168-7721 Ultrasonic
Wear Indicator III.

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


Charger (2) to the correct AC line voltage, either
120 Volts or 230 Volts, depending on use.
2. Connect charger connector (3) into the
CHARGE connector located on the top of the
Indicator III.

Place a piece of tape over the charge connector,


to prevent charging, when using alkaline
batteries.

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 9. Back View Of 168-7721 Ultrasonic Wear


Indicator III.

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


2. Remove battery cover (2).
12

Illustration 12. Enlarged View Of Battery Compartment.


(4) + or positive terminal.

The easiest way to install the batteries is to place


the () terminal of one battery against one of the
negative battery contacts (does not have a (+) sign
by it inside of the battery compartment (5).
Compress the negative battery contact as much as
possible (see Illustration 13) and then install the
plus terminal (+) of the battery into the battery
compartment.

Illustration 10. Indicator III With Battery Cover Removed.

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


batteries.
4. To install new batteries: The (+) terminal of the
battery must be placed on the battery contact
with the (+) symbol (4) (in the recessed area of
the battery compartment, as shown in
Illustration 11 and 12).

Illustration 13. Installing Battery Cover.


(5) Battery () negative terminal. (6) Battery (+) positive
terminal.

5. Install battery cover (2) and replace two


screws (1).
Illustration 11. Indicator III With Batteries Removed.
(4) + or positive terminal.

13

Connecting to DC Power
1. The optional 156-1077 Power Inverter (12 VDC)
may be used to connect the 168-7721 Indicator
to an external DC power source.
2. Plug the power plug of the 4C-3024 Battery
Charger into one of the two outlets on the
156-1077 Power Inverter. Refer to Illustration
8 and 14.
3. When using the battery from a machine or
engine as the power source, power the emission
analyzer by connecting the power cable clip
with the black colored handle to the machine or
engines frame or to the battery's negative
terminal. Connect the power cable clip with the
red colored handle to the battery's positive
terminal.
Illustration 14. 156-1077 Power Inverter.
(1) Power inverter. (2) Cigarette lighter adapter.
(3) Manual. (4) Battery power clips attached to cable.
(5) Installed fuse. (6) Extra fuses. (7) Two outlets that
accept the power cable's plug supplied with the
emission analyzer. (8) ON/OFF switch.

NOTICE
The 156-1077 Power Inverter requires a 12 VDC
input. Make sure not to exceed this specification
or the power inverter's fuse may blow resulting
in possible damage to the power inverter. Also,
reverse polarity could damage the power
inverter, but will most likely blow the 35 Ampere
fuse. Refer to item 5, illustration 9.
4. The 168-7721 Indicator can also be powered by
a vehicle's 12 VDC cigarette lighter. Remove
the cable with the power clips from the power
inverter. The power inverter can now be
plugged into a cigarette lighter on a vehicle.
Refer to Illustration 14.

14

Care and Cleaning of 168-7721


Indicator III

Cleaning the Case and Front Panel


Key Pad

The 168-7721 Ultrasonic Wear Indicator III is a


durable hand-held instrument. However, since it
will be used outdoors in a wide range of conditions,
care must be taken to protect it and keep it clean.

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.

The case is water resistant, but not waterproof, and


the instrument can be damaged if water is allowed
to enter the case. If moisture does enter the case,
the Indicator III should be allowed to dry out.
Remove the rear cover and battery cover and allow
it to dry completely in a warm, dry area.

Care of Connectors

Keep the Indicator III stored in the carrying case


when not in use.

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.

Removing the 9U-7981 Couplant


Residue

During use, the PROBE connector is protected by


the probe cable connector. Leave the probe
connected during storage so dirt does not enter.

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 RS232 connector is shipped with a plastic cap


on it. Keep this cap in place at all times when this
connector is not being used. Extra plastic caps are
included with the group.

The couplant is water soluble and a damp cloth


can be used to remove any residue that has dried.
However, care must be taken so no water enters
the Indicator III case.

15

Operating Instructions for


168-7721 Indicator 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


4C-5485 Ultrasonic Probe Cable into the probe
connector on the top of the Indicator III.

Calibrating the Indicator III and Probe

Turn the Indicator III ON

Before taking measurements, the accuracy of the


Indicator III and probe must be checked and the
Indicator III and probe recalibrated, if needed.

1. Press and release the ON/OFF key.

CATERPILLAR
INC.
COPR.
1989-1999

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.

Copyright Display.

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.

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.

If other materials are measured, the velocity must


be changed and a different PROBE CAL value
used. Refer to Ultrasonic Velocity Adjustment in
this manual.

MACH (CLEAR)

MACH Display (memory clear).

3. The MACH number (in the upper left hand


corner of the display) will be the one in use
when the instrument was last turned OFF.
If internal memory for the machine number
shown is clear (contains no stored information),
it will appear as the MACH display, as shown in
Step 2.

15

MACH
D8N
9TC1840

MACH Display (last machine used).

4. The example, in step 3, shows the MACH


display with the model and serial (product
identification) number of the last machine used
shown.
The MACH(ine) number may be selected with
the up arrow or down arrow keys.

Illustration 15. Applying Couplant To Ultrasonic Probe.

16

15
0.25

MACH (CLEAR)

Probe Removed From Calibration Disk.

5. If the calibration is correct, as shown in step 4,


proceed to the Undercarriage Measurement
Procedure section.
6. To calibrate the Indicator III and probe, press
the PROBE CAL key. The display should now
show (PROBE).

(PROBE)
PROBE CAL Key Pressed.
Illustration 16. Ultrasonic Wear Indicator III And Probe
Being Calibrated.

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 Illustration 16.

A metal calibration disk, Illustration 16, is used to


check the accuracy and calibrate the Indicator III
and probe.

15
MACH (CLEAR)
0.24 IN

1. Place a small amount of 9U-7981 Couplant on


the sensing end of the probe.
See Illustration 15.

Calibration Complete.

2. Press the probe against the metal calibration


disk on the top of the Indicator III.
See Illustration 16.

8. The MEASURED VALUE, shown in step 7,


should now be correct. If not, repeat this
procedure until it is correct.

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.

9. Once the correct value appears, the wear


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

15
MACH (CLEAR)
0.24 IN
Probe On Calibration Disk NOT In Calibration.
NOTE: The thickness value and its units
(i.e. 0.25 IN) flash while the probe is coupled and
the beeping sound occurs at the same rate.

4. The display value should be 6.3 mm or (.25 in)


when in the Low Resolution Mode. If it is not
correct, as shown in step 3, follow the
instructions in Step 6.

17

Undercarriage Measurement
Procedure

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: When using this procedure, refer to the


Undercarriage Measurement Display Map in this
manual, for additional information on the sequence
of the displays.

CLR ALL MACH

1. The Indicator III MUST be calibrated before any


measurements are taken. Refer to Calibrating
the Ultrasonic Wear Indicator III section.

Display while all machines are being cleared

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. The display will then be replaced with the


(CLEAR) message indicating the memory has
been cleared and is ready for new data.

Clearing the Memory

Using LOC(ation) Mode of


Operation

1. If a (CLEAR) machine cannot be located, any


one or all machine(s) can be cleared by first
pressing and releasing the red SHIFT key and
then pressing CLR MACH key.

To store ultrasonic measurements and input


information about the machine being measured, the
Indicator III must be in the LOC(ation) mode of
operation.

CLR MACH 2
CLR ALL MACH

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.

2. Press the VALUE key to clear one machine


(Machine 2 in this example).

Once in the LOC(ation) mode, the 71 different


undercarriage storage locations shown in the
List of Undercarriage Storage LOC(ation)
Displays are available for use. These storage
locations can be accessed with the up and down
arrow keys. Refer to the Undercarriage
Measurement Display Map in this manual for
additional information on how to change between
the various displays.

CLR MACH 2
Display while one machine is being cleared.

The message shown above will appear on the


display for a short period of time.
3. The (CLEAR) message indicates the memory
has been cleared and is ready for new data.
NOTE: When a MACH memory is cleared, the data
that was in the memory for that MACH number will
be lost and cannot be retrieved.

MACH (CLEAR)

MACH Display After Clearing Machine Memory.

18

List of Undercarriage Storage


LOC(ation) Displays
Loc.
1
2
3

Display

MODEL
SERIAL NUMBER
DATE MM/DD/YYYY
DATE DD/MM/YYYY
HOURS

HRS. / WEEK

MILES
KM
MILES/WEEK
KM/WEEK
JOB SITE
IMPACK COND

7
8
9

10

ABRASIVE COND

11

MOISTURE COND

11

PACKING COND

13

BUSHING ALLOW

14
15
16
17

L
L
L
L

18
19

L BUSHING EXT
BUSHING TOOL

20
21

L SHOE
SHOE TOOL

22

F IDLER DEPTH

23

F IDLER SONIC

24
25
26
27
28
29

R IDLER DEPTH
R IDLER SONIC
L CAR. ROLL 1
L CAR. ROLL 2
L CAR. ROLL 3
CAR ROLL TOOL

30
31
32
33
34

L
L
L
L
L

TRACK SAG
DRY JOINTS
LINK
BUSH INT

ROLLER
ROLLER
ROLLER
ROLLER
ROLLER

1
2
3
4
5

Loc.

Notes
The machine model number
The machine serial number
The date by month, day, year
The date by day, month, year
The service hour meter reading
on the machine
The number of hours the
machine has worked per week
The reading on the machines
odometer in miles or kilometers
The distance the machine has
traveled per week
The location of the machine
The underfoot conditions Impact, use SET DIGIT:
MODERATE, HIGH, LOW
The underfoot conditions Abrasive, use SET DIGIT:
MODERATE, HIGH, LOW
The underfoot conditionsMoisture, use SET DIGIT:
MODERATE, HIGH. LOW
The underfoot Conditions
Packing, use SET DIGIT:
MODERATE, HIGH. LOW
Bushing allowable wear, use SET
DIGIT: GREATER, LESSER
Left track sag - use SET DIGIT
Left dry joints - use SET DIGIT
Left link measurement
Left bushing internal wear - use
SET DIGIT
Left bushing external wear
Measuring tool used on bushings
(EXT). SET DIGIT: ULTRASONIC,
CALIPER, DEPTH GAUGE
Left shoe measurement
Measurement tool used on
shoes, SET DIGIT:
ULTRASONIC, DEPTH GAUGE
Front idler depth gauge
measurement - use SET DIGIT
Front idler ultrasonic
measurement - use SET DIGIT
Rear idler depth gauge meas.
Rear idler ultrasonic measurement
Left carrier roller number 1
Left carrier roller number 2
Left carrier roller number 3
Measuring tool used on carrier
rollers. SET DIGIT:
ULTRASONIC, CALIPER
Left track roller number 1
Left track roller number 2
Left track roller number 3
Left track roller number 4
Left track roller number 5

Display

35
36
37
38
39
40

L ROLLER 6
L ROLLER 7
L ROLLER 8
L ROLLER 9
L ROLLER 10
ROLLER TOOL

41
42
43
44
45

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

46
47
48

A BUSHING EXT
R SHOE
F IDLER DEPTH

49

F IDLER SONIC

50

R IDLER DEPTH

51

R IDLER SONIC

52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71

A CAR. ROLL 1
R CAR. ROLL 2
A CAR. ROLL 3
A ROLLER 1
R ROLLER 2
R ROLLER 3
R ROLLER 4
R ROLLER 5
A ROLLER 6
R ROLLER 7
R ROLLER 8
R ROLLER 9
R ROLLER 10
R SPROCKET
NOTES LINE 1
NOTES LINE 2
NOTES LINE 3
NOTES LINE 4
SPARE #1
SPARE #2

Notes
Left track roller number 6
Left track roller number 7
Left track roller number 8
Left track roller number 9
Left track roller number 10
Measuring tool used on track
rollers. SET DIGIT:
ULTRASONIC, CALIPER, DEPTH
GAUGE
Left sprocket - use SET DIGIT
Right track sag - use SET DIGIT
Right dry joints - use SET DIGIT
Right link measurement
Right bushing internal wear use SET DIGIT
Right bushing external wear
Right shoe measurement
Front idler depth gauge
measurement - use SET DIGIT
Front idler ultrasonic
measurement
Rear idler depth gauge
measurement - use SET DIGIT
Rear idler ultrasonic
measurement
Right carrier roller number 1
Right carrier roller number 2
Right carrier roller number 3
Right track roller number 1
Right track roller number 2
Right track roller number 3
Right track roller number 4
Right track roller number 5
Right track roller number 6
Right track roller number 7
Right track roller number 8
Right track roller number 9
Right track roller number 10
Right sprocket - use SET DIGIT
16 characters - use SET DIGIT
16 characters - use SET DIGIT
16 characters - use SET DIGIT
16 characters - use SET DIGIT
For extra measurement
For extra measurement

NOTE: The Setting Menu is used to change how


the Date (location 3), the Distance (location 6), and
the Distance per Week (location 7) are displayed.

19

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.

MODEL
---------

MODEL display with empty MODEL number.

The same procedure will be used for entering:

DATE

MODEL
D8N

HOURS
HRS. PER WEEK

MODEL display containing MODEL number.

MILES or KM
MILES PER WEEK or KM PER WEEK

The first storage location is MODEL. This display is


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

JOB SITE . . . and

Changing Displays with Words


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

Entering Information into the


Indicator III

If the memory contains a MODEL number, it will


always be shown on the display. If it does not
contain a MODEL number, dashed lines will show
where the number should be entered.

IMPACT COND
2 MODERATE

Example of IMPACT with alternate word


MODERATE.

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.

IMPACT COND
2
HIGH

Example of IMPACT with alternate word HIGH.

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.

IMPACT COND
2
LOW

Example of IMPACT with alternate word LOW.

Continue this procedure until the entire MODEL


number is on the display. When finished, press the
SAVE key and the MODEL number will be stored in
memory.
After SAVE is pressed, the Indicator III will advance
the display to the next LOC(ation) display, which is
the SERIAL NUMBER.
To enter the serial (product identification) number
into the SERIAL NUMBER display, follow the same
procedure as used in the Using LOC(ation) Mode
of Operation section.
20

On these displays, alternate words are available.


To view the other words available, press the VALUE
key. The other words will appear, as shown in the
previous examples.

4. When you are satisfied a good value is on the


display, remove the probe and that value will
remain in the MEASURED VALUE display.
NOTE: Measurements can only be taken in the
MACH(ine) Display Mode or in a LOC(ation)
Display Modes screen that accepts ultrasonic
measurements.

To select and store the desired word in the memory,


leave it on the display and press the up arrow key
to move on to the next location. The selected word
will always reappear on the display when that
display is used again.

Saving Measured Values in


Memory
The measured value shown on the display can be
saved in the memory of the wear indicator by
pressing the SAVE key. After a (SAVE) indication
has flashed on the display, the next undercarriage
part to be measured will automatically appear on
the display.

Measuring Track Sag


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

To make sure that the number was recorded


correctly, press the down arrow key to go back to
the previous LOCATION. The value just measured
will show on the MEMORY VALUE display.

1. To enter this measurement at the L TRACK SAG


display, press the VALUE key.
2. The first digit of the MEMORY VALUE will flash,
allowing the measurement to be entered. Refer
to the topic Entering Information into the
Ultrasonic Wear Indicator III section.

NOTE: While taking an ultrasonic measurement,


once satisfied of a good measurement, press the
SAVE key before removing the probe.

Tool Displays

3. When the proper number has been entered,


press the SAVE key to continue with the next
reading.

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:

Taking Ultrasonic Measurements


The next LOC(ation) is L LINK (left link
measurement) and is the first measurement to be
taken with the ultrasonic probe.
NOTE: Refer to the Undercarriage Measurement
Techniques section, in this manual, for details on
how to measure each undercarriage component.

1
1

1. To take a measurement, place a small amount of


9U-7981 Couplant on the sensing end of the
probe and press it firmly and squarely against
the wear surface.

BUSHING TOOL
ULTRASONIC

Example of BUSHING TOOL with type of tool used:


ULTRASONIC

1
2

2. The measurement will appear on the display


above MEASURED VALUE.

BUSHING TOOL
CALIPER

Example of BUSHING TOOL with type of tool used:


CALIPER

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.

1
3

BUSHING TOOL
DEPTH GAUGE

Example of BUSHING TOOL with type of tool used:


DEPTH GAUGE

NOTE: The thickness value and its units


(i.e. 4.92 IN) flash while the probe is coupled and
the beeping sound occurs at the same rate.
21

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.

Pressing the VALUE key will select CALIPER or


DEPTH GAUGE. Select the tool to be used and
then press the up arrow key to move to the next
display and the selected tool will be put in memory.
Continue through the LOCATION displays until all
of the undercarriage measurements have been
taken and recorded.

6. Saving ultrasonic measurements can be done


either while holding the probe on the part or
after removing the probe. If you prefer to
remove the probe before pressing SAVE, pull
the probe off quickly to prevent the
measurement from increasing slightly as the
probe is removed.

Spaces for notes and two extra measurement


storage locations have been provided at the end of
the measurement sequence.
When finished with the measurements, advance to
the next machine by pressing LOC/MACH and the
up arrow key.

Measurement Operating Tips


The following operating tips will make it easier to
take measurements with the Indicator III.
1. The sequence of the undercarriage storage
locations were selected to easily transfer into
the Custom Track Service personal computer
program. Until you have this program, it may
save time to enter and save only the serial
number and measurements in the Indicator III.
Then manually record the data for locations 2
through 13 directly on the CTS Form. Refer to
the topic entitled List of Undercarriage Storage
Location Displays section.
After taking the measurements, scroll through
the stored measurements while manually
recording them on the CTS form.
2. When using the arrow keys, press and release
the keys to change the display slowly, or hold
the key down to scroll rapidly.
3. For users preferring not to use the memory
feature, ultrasonic measurements can be taken
at any time regardless of the LOC(ation) or
MACH(ine) settings.
When taking measurements, the 9U-7981
Couplant must be applied to the sensing end of
the probe before measuring a component.
4. To couple the ultrasonic probe to a component,
it is important to have the 9U-7981 Couplant
between the sensing end of the probe and the
component. The probe tip surface must be flat
(square) with the part being measured. It may
be easier to hold the probe properly if a finger is
held on top of the probe.

22

Undercarriage Measurement
Techniques
Track Links

Illustration 19. Probe Located On The Tip Of The


Grouser.

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


grouser to the bottom of the plate.

Illustration 17. Measuring Track Links.

3. On double grouser and triple grouser shoes, do


not measure the rear grouser due to
interference with the trailing edge.

1. Measure distance from tread surface to bushing


bore.

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.

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


3. Slide the probe along the tread surface and
take the smallest reading.

Track Shoes

Track Bushing

Illustration 18. Probe Located On The Bottom Of The


Plate.

Illustration 20.

1. Measure the wall thickness.

1. Measure the distance from the bottom of the


plate to tip of the grouser.

2. Slowly slide the probe around the reverse drive


side to find the smallest dimension and save
this measurement.
3. Next, slide the probe around the vertical and
forward drive sides to check if the measurement
is smaller (indicating more worn). Always save
the smallest measurement.
23

Idler

Illustration 23.
Illustration 21.

1. Measure the center flange thickness only on


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

Carrier Roller

Illustration 24. Measure Distance From The Outside Of


Tread Surface To The Bore.

Three Piece Rims

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 22. Measure The Thickness Of Press-On Rim.

24

Track Roller

Measuring the Thickness of Parts


Other than Undercarriage
In addition to measuring undercarriage wear, the
Ultrasonic Wear Indicator III can be used to
measure steel part thickness without changing any
settings. This is simple to do because the wear
indicator is designed to always show the
MEASURED VALUE regardless of which keys have
been pressed. This allows a nonexperienced
person to take readings.
Examples where this may be used are to check the
wall thickness of a:
Bulldozer blade

Illustration 25.

Bucket base edge


Scraper bowl

1. Measure the distance from the tread surface to


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

NOTE: In addition to measuring steel parts, many


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

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.

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.

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

3. To check the accuracy of the reading, measure


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

25

Transferring the Memory


Values to or From a Computer

Settings Menu
The Settings Menu is a special menu to change
specific functions for the wear indicator. Enter the
Settings Menu by pressing and releasing the blue
SHIFT key and then pressing the SAVE/SET key.
The Settings Menu flow chart is shown as
illustration 26. The Settings Menu contains these
functions in this order: Resolution, Turnoff, Velocity,
Serial, Beeper, Language, Distance, and Date.
Resolution is the first function displayed when
entering the Settings Menu. Press the up down
arrow to scroll forward through the Settings Menu
or up arrow to scroll backwards through the
Settings Menu. Illustration 27 shows the different
settings that can be selected with each function in
the Settings Menu.

The information contained (saved) in the


Indicator IIIs memory may be transferred to an IBM
or compatible personal computer for storage or
printing using the Custom Track Service (CTS)
personal computer program.
When transferring machine data from an IBM or
compatible personal computer using the Custom
Track Service (CTS) program:
1. The Indicator III does not clear all 64 machines
before transferring new machine data from the
PC. The CLR ALL MACH function may be used
to manually clear all 64 machines before the
transfer.

Resolution

2. The user can select where the machines data


will be stored in the Indicator III by scrolling to
the Machine No. before the transfer. The
Indicator III will then store the transferred data
from the machine(s) beginning with the
MACH(ine) No. shown on the Indicator IIIs
display.

Allows the measurement resolution to be in a high


or a low mode.
1. Low Resolution mode (default position) is
0.0 MM [0.00 IN].
2. High Resolution mode is 0.00 MM [0.000 IN].

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.

Turnoff
This function allows for longer battery life by
automatically turning the Indicator III OFF if it has
not been used for five minutes. Normal operation
of the key pad ON/OFF switch is not affected.
1. MANUAL - Indicator III only turns OFF by using
the "ON/OFF" key switch.

NOTE: When transferring machine data from a PC


to the Indicator III, the Indicator III does not wrap
around the 64 MACH(ine) locations, i.e. the data
from three machines is transferred from the PC,
MACH(ine) memory in the Indicator III is not empty,
and the Indicator III's displays MACH(ine) 63. The
first machine transferred will be stored in
MACH(ine) 63, the second machine transferred will
be stored in MACH(ine) 64, and the third machine
will overwrite the second machine and be stored in
MACH(ine) 64.

2. AUTO (default position) - Indicator III


automatically turns off after 5 minutes and no
keys have been pressed or the probe has not
been coupled. The Indicator III will also turn off
by using the "ON/OFF" key switch.

Velocity
Allows the ultrasonic velocity to be viewed on the
display and changed using the front panel key
pad.
1. OFF - Velocity adjust disabled (default position).
2. ON - Velocity adjust enabled.

26

Serial

Language

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:

This function allows the language to be changed.


All of these languages are in the 168-7721
Ultrasonic Wear Indicator III and are selectable.
1. ENGLISH (default setting).
2. FRENCH.
3. GERMAN.
4. PORTUGUESE.

1. 1200.

5. SPANISH.

2. 9600 (default position).


3. 19200.

Distance

Beeper

Allows the units for distance to be changed:


1. MILES (default setting).

This function turns ON or OFF the beeper that


sounds when the probe is properly coupled to the
material being measured. When turned OFF,
coupling will still be indicated by MM or IN being
displayed beside the MEASURED VALUE when
properly coupled.

2. KM - Kilometers.

Date
This function allows date configuration to be
selected:

1. ON (default position).

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


setting).

2. OFF.

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

27

BLUE SHIFT + SET KEYS


(ENTER SETTINGS MENU)

RESOLUTION
0.0MM
[0.00IN]

DATE
MM/DD/YYYY
ARROW
KEYS

ARROW
KEYS

DISTANCE
MILES
ARROW
KEYS

LANGUAGE
ENGLISH
ARROW
KEYS

TURNOFF
AUTO

BEEPER
ON

ARROW
KEYS

VELOCITY
OFF

ARROW
KEYS

ARROW
KEYS

SERIAL
9600

BLUE SHIFT + SET KEYS


(EXIT SETTINGS MENU)

0730-35

Illustration 26. Settings Menu Operation (default states shown).

28

DEFAULT

DATE
MM/DD/YYYY

DEFAULT

VALUE KEY

DISTANCE
MILES
VALUE KEY

DATE
DD/MM/YYYY

DEFAULT

RESOLUTION
0.0MM
[0.00IN]

DISTANCE
KM

DEFAULT

VALUE KEY

TURNOFF
AUTO
VALUE KEY

RESOLUTION
0.00MM
[0.000IN]

DEFAULT

VELOCITY
OFF

TURNOFF
MANUAL

DEFAULT

VALUE KEY

BEEPER
ON
VALUE KEY

VELOCITY
ON

DEFAULT

BEEPER
OFF

VALUE KEY

SERIAL
9600
VALUE KEY

SERIAL
19200

DEFAULT

LANGUAGE
ENGLISH

SERIAL
1200

VALUE KEY

LANGUAGE
VALUE KEY

VALUE KEY

VALUE KEY

LANGUAGE
FRENCH

LANGUAGE
SPANISH

VALUE KEY

VALUE KEY

LANGUAGE
GERMAN

VALUE KEY

LANGUAGE
PORTUGUESE
0730-36

Illustration 27. Settings Menu Operation.

29

Ultrasonic Velocity
Adjustment

The velocity setting of the Indicator III will appear


on the bottom line of the display, as shown above.
Either MM or IN will be displayed, depending on
which was being used earlier.

Adjustment of the velocity calibrates the


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

3. If the Indicator III is being used to measure


Undercarriage Steel, be sure it reads
5.87 MM/SEC or (.231 IN/SEC), as shown in
Step 2.

Ultrasonic Velocity is the speed in Millimeters per


microsecond (MM/SEC) or inches per
microsecond (IN/SEC) that sound travels through
different materials.

If the number is not correct, or you plan to


measure other materials, the velocity number
can be changed. Refer to the Changing the
Ultrasonic Velocity section.

Refer to Chart E for a list of various materials,


ultrasonic velocities, and probe calibration values.

Changing the Ultrasonic Velocity


1. Locate the velocity number for the material to be
measured in Chart E. The numbers given in
Chart E are approximate, and slightly different
numbers may have to be used to give accurate
readings because of differences in material
composition.

Chart E.

Material

Velocity
EC
MM/
SEC)
(IN/

Probe CAL1
Measured Value

Aluminum

6.09 (.240)

6.3 mm (.25 in)

Cast Iron

4.57 (.180)

4.8 mm (.19 in)

Copper

4.57 (.180)

4.8 mm (.19 in)

Glass

5.33 (.210)

5.6 mm (.22 in)

Mild Steel

5.84 (.230)

6.3 mm (.25 in)

Plastic (Plexiglass)

2.67 (.105)

2.8 mm (.11 in)

Stainless Steel

5.84 (.230)

6.3 mm (.25 in)

Tin

3.30 (.130)

3.6 mm (.14 in)

Undercarriage Steel

5.87 (.231)

6.3 mm (.25 in)

2. With the display showing the velocity, as shown


in Step 2 in Checking the Ultrasonic Velocity,
press the VALUE key. The first digit of the
velocity number will flash. Use the number keys
to set the velocity to the desired number.
3. When the desired velocity number is shown on
the display, press the SAVE key and the
Indicator III will now be set for the new material.
4. Calibrate the probe for this new material by
pressing the PROBE CAL key. Then place the
probe, with couplant applied to the sensing end
of the probe, on the calibration disk. The
number shown as the MEASURED VALUE on
the display should be the value shown on the
Velocity chart under PROBE CAL. MEASURED
VALUE for the new material. Every time the
calibration disk is measured with this new
velocity setting, this reading should appear on
the MEASURED VALUE display instead of
6.3 mm or (.25 in).

1This

is the value that will show at MEASURED


VALUE on the display when the metal calibration
disk is measured for each velocity listed.

Checking the Ultrasonic Velocity


1. Enter the Settings Menu and change the
VELOCITY from OFF to ON (refer to the Settings
Menu section).
2. With the Indicator III ON, make sure display is in
the MACH(ine) display mode, then press the
MM/INCH key.

5. Measure a known thickness of the new material


with the Indicator III to be sure the readings are
accurate.

1
MACH (CLEAR)
VEL=5.87
MM/USEC

6. If the readings are not exact, change the


velocity setting number right-hand digit by one
and recalibrate.

Example of Screen Display with VEL in MM/SEC.

7. Measure the material again and continue this


process until the Indicator III reads correctly.

1
MACH (CLEAR)
VEL=.231
IN/USEC
Example of Screen Display with VEL in IN/SEC.
30

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 Volts. A value of 0%
will be displayed anytime the battery voltage falls to
5.4 Volts or less. The Battery Level Monitor screen
will appear as follows:

The Indicator III will remember the last MACH(ine)


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

Factory Reset

BATTERY POWER
70 PERCENT

This function will reset the Indicator III back to the


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

NOTE: If using NiCad rechargeable batteries, they


must be fully charged before each use for the
Battery Level Monitor to work correctly. Refer to
Charging the Internal NiCad (rechargeable)
Batteries section.

Low Battery Indication

Viewing the Software Version


Screen

The LCD display will flash for at least 30 seconds


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

The version number of the software used in the


Ultrasonic Wear Indicator III can be viewed on the
display in the following manner.
1. Turn the Indicator III OFF.
2. Press and hold the LOC/MACH key, then press
ON/OFF to turn the Indicator III ON.

SOFTWARE
3.1

NOTE: If using NiCad rechargeable batteries, they


must be fully charged before each use for the Low
Battery Indication to work correctly. Refer to
Charging the Internal NiCad (rechargeable)
Batteries section.

VERSION

Example of Screen Display for SOFTWARE


VERSION number.

NOTE: When the probe is coupled and the


Indicator IIIs battery power is low, the beeping
sound will be heard at half rate. The beeping
sound occurs when the entire display flashes
during a low battery indication.

3. When the Indicator III comes ON, the Software


Version screen is displayed, as shown in step 2.
To leave this screen, turn the Indicator III OFF.
The software is the program that operates the
microprocessor in the Indicator III. It is
contained nonvolatile, located in the
Indicator III, so removing the batteries for an
indefinite period of time will not affect the
memory.
31

Checking the Operation of the


Indicator III

Adjusting the Display's


Contrast

The following procedure may be used to check the


operation of the 168-7721 Ultrasonic Wear Indicator
III and the 168-7722 or 4C-5485 Probe. The only
components required for the test are the 168-7721
Ultrasonic Wear Indicator III, 168-7722 or 4C-5485
Probe, and 9U-7981 Couplant.

The display's contrast may be adjusted to the


user's preference. The contrast has been set at the
factory. If it is determined it needs to be changed,
use the following procedures:
1. Remove six screws from the back cover and
remove the cover.

Perform all the procedures, as shown in Operating


Instructions for the 168-7721 Ultrasonic Wear
Indicator III, in this manual.

2. Locate contrast adjustment (Illustration 28) on


the top of the printed circuit board. It is one of
only two screwdriver adjustments and is located
below the calibration block and is labeled RP2
on the printed circuit board.

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.

3. Before turning this adjustment, observe the


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

Alternate Method
An alternate method is to measure a known
thickness of undercarriage steel.
1. Check the display of the undercarriage storage
locations for one machine. During this test, use
all front panel keys to be sure they operate
correctly.

4. To adjust the display's contrast, use a small flat


head screwdriver to turn the contrast while
viewing the display's screen. Continue to adjust
until the information on the screen is clear to the
user's preference. Once the setting is obtained,
replace the rear cover.

If the Indicator III does not operate properly


during this test, refer to the Troubleshooting
section in this manual.
2. Next, test the Indicator III on actual
undercarriage components. Correct
measurements should appear on the
MEASURED VALUE display without having to
move the probe back and forth.
3. Also check to see that measurements can be
taken on very thick undercarriage components
such as through track shoe grouser bars.
4. If the Indicator III has trouble making any of
these readings, the gain may need to be
adjusted. Refer to the Troubleshooting section
in this manual for the procedures to adjust the
gain.
5. This completes the test of the Indicator III.

Illustration 28. Cover removed to access the gain and


display's contrast adjustments.
(1) RP1 Gain adjustment. (2) RP2 Display's contrast
adjustment.

32

Adjusting the Gain

Troubleshooting

If the gain is out of adjustment. it will result in


inaccurate or hard to get readings, or no echo. If it
is determined the gain needs to be changed, use
the following procedures:

If the Indicator III does not operate properly, first


check the Battery Level Monitor to see if the
batteries have sufficient power remaining. If not,
and NiCad batteries are installed, then recharge or
replace them with new alkaline batteries.

NOTE: The gain adjustment is set at the factory


using precision instruments and should not be
changed unless absolutely necessary.

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.

1. Remove six screws from the back cover and


remove the cover.
2. Locate gain adjustment (Illustration 28) on the
top printed circuit board.

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.

3. Before turning this adjustment, check and see if


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

If the Battery Level Monitor shows the batteries


have sufficient power remaining and the
Indicator III still will not turn ON, it must be sent in
for repair. Refer to the Service section in this
manual.

4. Make sure the beeper is ON, which is selected


as ON or OFF in the Settings menu.

If the display comes on but the Indicator III will not


take measurements, the problem may be in 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.

If you have another probe that is known to be


good, try it and see if it works. If not, use the
following procedures:
1. Take the Indicator III to a quiet place.

a. Turning the adjustment clockwise (right)


decreases the gain until no echo is received
(no beeping sound heard and no
measurement taken).

2. Put the probe close to your ear.


3. Turn the Indicator III ON.
4. You should hear a high frequency sound
emitted by the probe.

b. Turning the adjustment counterclockwise (left)


increases the gain.

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.

NOTE: If the gain is increased too much, the


beeper will not turn OFF when the probe is
removed from the component being measured.

c. The correct setting is when the gain control is


set to the most counterclockwise position that
will allow readings to be taken easily, and the
beeping stops when the probe is removed. It
may take some trial and error and trying
various component measurements before the
best setting is obtained.

6. 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.

6. Once this setting is obtained, replace the rear


cover.

33

Undercarriage Measurement Display Map


NOTE: Settings menu in default states.

KEYS

HOLD

PUSH

PUSH

LOC
MACH

ON
OFF

ON
OFF

SOFTWARE VERSION
3.1
MACHine
DISPLAYS

(CLEAR)

LOCation
DISPLAYS

MACH

(CLEAR)

ON
OFF

FACTORY RESET

TYPICAL
DISPLAYS

VALUE
KEY

MODEL

ARROW
KEYS

ARROW
KEYS

CLR
CLR
MACH

CATERPILLAR INC.
COPR.
1989-1999

LOC/MACH
KEY

MACH

PUSH AND HOLD BOTH KEYS


AT SAME TIME FOR 3 SECONDS

MODEL

RED
SHIFT "D" KEY

1
SERIAL NUMBER

MODEL
D

"9" KEY

MACH

(CLEAR)

MACH

(CLEAR)

MACH

1
DATE

MM/DD/YYYY
01 / 01 / 1999

MODEL
D

HOURS

MODEL
D9

HRS. / WEEK

(CLEAR)

MILES

MILES / WEEK

SAVE
KEY

MODEL
D9

1
JOB SITE

63

MACH

(CLEAR)

64

MACH

(CLEAR)

IMPACT COND
2
MODERATE

ABRASIVE COND
2
MODERATE

VALUE
KEY

ARROW
KEYS

1
3

IMPACT COND
HIGH

IMPACT COND
LOW

MOISTURE COND
2
MODERATE

TO PACKING COND
DISPLAY
0730-30

34

LOCation Display Map


NOTE: Settings menu in default states and units are inches.
FROM MOISTURE COND
DISPLAY

PACKING COND
2 MODERATE

ARROW KEYS

ARROW KEYS

R IDLER SONIC
0.00
0.00IN

TRACK SAG
0.00IN

L CAR. ROLL 1
0.00
0.00IN

L DRY JOINTS

L CAR. ROLL 2
0.00
0.00IN

L CAR. ROLL 3
0.00
0.00IN

BUSHING ALLOW
2
GREATER

L
0.00

R IDLER DEPTH
0.00
0.00IN

1
0.00

L LINK
0.00IN

1
L BUSHING INT
0.00
0.00IN

1 CAR ROLL TOOL


1
ULTRASONIC

1 L BUSHING EXT
0.00
0.00IN

1
1

BUSHING TOOL
ULTRASONIC

VALUE
KEY

1
2

BUSHING TOOL
CALIPER

0.00

L ROLLER 1
0.00IN

0.00

L ROLLER 2
0.00IN

0.00

L ROLLER 3
0.00IN

0.00

L ROLLER 4
0.00IN

0.00

L ROLLER 5
0.00IN

0.00

L ROLLER 6
0.00IN

VALUE KEY

1
0.00

L SHOE
0.00IN

ARROW
KEYS

1
3

BUSHING TOOL
DEPTH GAUGE

1
1

SHOE TOOL
ULTRASONIC

F IDLER DEPTH
0.00
0.00IN

F IDLER SONIC
0.00
0.00IN

0730-31

TO L ROLLER 7
DISPLAY

35

LOCation Display Map (contd)


FROM L ROLLER 6
DISPLAY

L ROLLER 7
0.00IN

0.00

ARROW KEYS

F IDLER DEPTH
0.00
0.00IN

ARROW KEYS

1
0.00

R ROLLER 6
0.00IN

ARROW KEYS

F IDLER SONIC
0.00
0.00IN

R IDLER DEPTH
0.00
0.00IN

R IDLER SONIC
0.00
0.00IN

R CAR. ROLL 1
0.00
0.00IN

SPROCKET

R CAR. ROLL 2
0.00
0.00IN

1 R TRACK SAG
0.00
0.00IN

R CAR. ROLL 3
0.00
0.00IN

1
NOTES LINE 1

1
0.00

R ROLLER 1
0.00IN

1
NOTES LINE 2

0.00

R ROLLER 2
0.00IN

1
NOTES LINE 3

0.00

R ROLLER 3
0.00IN

1
NOTES LINE 4

R ROLLER 4
0.00IN

0.00

R ROLLER 5
0.00IN

0.00

L ROLLER 8
0.00IN

0.00

L ROLLER 9
0.00IN

0.00

L ROLLER 10
0.00IN

0.00

1
1

ROLLER TOOL
ULTRASONIC

R DRY JOINTS
21

R LINK
0.00IN

1 R BUSHING INT
0.00
0.00IN

1 R BUSHING EXT
0.00
0.00IN

1
0.00

0.00

R SHOE
0.00IN

0.00

R ROLLER 7
0.00IN

0.00

R ROLLER 8
0.00IN

0.00

R ROLLER 9
0.00IN

R ROLLER 10
0.00
0.00IN

SPROCKET

0.00

SPARE #1
0.00IN

0.00

SPARE #1
0.00IN
END

BACK TO START
MODEL DISPLAY

0730-32

36

9U-7981 Couplant Material


Safety Data Sheet

Section 6 Health Hazard and First Aid


Data
Routes of Entry1:

(To comply with 29 CFR 1910, 1200)


Effective Date: 2/98
N/A = not applicable or not available

Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . not likely


Ingestion . . . . . . . . . . . . . . . . . . . . . . not normally
Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . not normally

Section 1 Product Identification

Inhalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no

Product Name . . . . . 9U-7981 Ultrasonic Couplant

Effects of Overexposure:

Generic Name . . . . . . . . . . . . Ultrasound Couplant

Acute . . . . . . . may cause temporary eye irritation

NFPA Hazardous Materials Identification System (est)

Chronic . . . . . . . . . . . . . . . . . . . . . none expected

Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

First Aid Procedures:

Flammability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

Skin . . . . . . . . . . . . Remove with water if desired.

Reactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

Eyes . . . . . . . . . . Flush with water for 15 minutes.

Section 2 Hazardous Ingredients

Ingestion . . . . . . . . . . For large quantities, induce


vomiting and call a physician.

None

Inhalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

Section 3 Physical Data (nominal)


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

Section 7 Storage and Handling


Information

Vapor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . N/A

Precaution to be taken in handling and storage:

Boiling Point . . . . . . . . . . . . >220F pH: 7.35 to 7.9

Store between 20F and 120F. Spills are slippery


and should be cleaned up immediately.

Vapor Density . . . . . . . . . . . . . . . . . . . . . . . . . . N/A


Evaporation Rate . . . . . . . . . . . . . . . . . . . . . . . N/A
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . >1.02

Steps to be taken in case material is released or


spilled:

Solubility in Water . . . . . . . . . . . . . . . . . . Complete

Pick up excess for disposal. Clean with water.


Waste disposal method:

Appearance and Odor . . Water white, opaque gel;


bland odor

Dispose of in accordance with federal, state, and


local regulations.

Section 4 Fire and Explosion Hazard


Data

Section 8 Control Measures

Flash Point . . . . . . . . . . . . . . . . . . . . . . . . . . . none

Respiratory Protection . . . . . . . . . . . . . not required

Upper Exposure Limit . . . . . . . . . . . . . . . . . . . none

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

Lower Exposure Limit . . . . . . . . . . . . . . . . . . . none

Protective Gloves . . On individuals demonstrating


sensitivity to 9U-7981 Couplant.

Special Fire Fighting Procedures . . . . . . . . . . . N/A


Extinguishing Media . . . . . . . . . . . . . . . . . . . . . N/A

Eye Protection . . . . . . . . . . . . . . . . . As required by


working conditions

Unusual Fire and Explosion Hazards . . . . . . . none

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

Section 5 Reactivity Data


19U-7981

Ultrasonic Couplant contains only food


grade and cosmetic grade ingredients.

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stable
Conditions to Avoid . . . . . . . . . . . . . . . . . . . . . none
Incompatibility (Materials to Avoid) . . . none known
Hazardous Polymerization . . . . . . . . . will not occur
Hazardous Decomposition or Byproducts . . . none
known

37

Service
If the Ultrasonic Wear Indicator III does not operate
correctly, recharge or replace the internal NiCad
batteries with new ones and check the operation.
If it still does not operate, refer to the
Troubleshooting section in this manual. If the
Indicator III is found to be faulty, contact Dealer
Service Tools for information on how to obtain the
needed repair service.
Dealer Service Tools provides the instrument's user
with a warranty of one year from purchase date. If
the reason for failure is determined to be abuse,
the warranty is declared void. Any out-of-warranty
repairs will be charged to the owner.
For any product support questions with your
instrument, contact Dealer Service Tools at:
501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com
If the instrument, or any part of it needs repair, then
contact and send it to:
ATS (Advanced Technology Services)
8201 North University Avenue
Peoria, Illinois USA 61615
Phone: (800) 328-7287 (Inside USA)
(309) 693-4000
Fax:
(309) 693-4170
E-mail repair@advancedtech.com"

38

NOTES

39

For information on service tools or shop supplies,


contact Dealer Service Tools on:
Dealer Service Tools
501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com

2005 Caterpillar
All Rights Reserved

NEHS0730-02
Printed in U.S.A.

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