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 Display’s 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
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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 part’s 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.
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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.
4
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.
1
168-7721
2
168-7722
PEKP9400
Custom Track Service Handbook: Fits under Indicator III
2
5P-3277
Ultrasonic Probe (Declaration of Conformity not shown)
Tape Measure: 3 mm (10 ft) for pitch, sag, and sprocket measurement
3
8H-8580
Scraper: For cleaning undercarriage components
4
5P-8616
Sprocket Gauge: For D4, D5, and D6 Track-type Tractors
5
5P-8617
Sprocket Gauge: For D7, D8, and D9 Track-type Tractors
6
6V-9410
Depth Gauge: For measuring idlers
—
5P-3920
Steel Rule: 300 mm (12 in), store on top of 9U-6000 Paper Towels
9U-7981
Couplant
6V-7145
Carrying Case
5
4C-4772
Foam Insert
6
4C-3024
Battery Charger (110/220 Volts AC, 50/60 Hz)
7
—
—
—
—
NEHS0730
Description
1
Description
4
NEEG2835
Part No.
Ultrasonic Wear Indicator III (Calibration Certificate not shown)
3
—
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.
5
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
1
4C-5488
Cable Assembly RS232 (PC AT Version): For connecting the 168-7721 to an IBM AT, or compatible, personal computer. Has 9-pin, type D connector (DB9F).
2
4C-5489
Cable Assembly RS232 (PC XT Version): For connecting the 168-7721 to an IBM XT, or compatible, personal computer. Has 25-pin, type D connector (DB25F).
3
4C-5897
Cable Assembly RS232 (Modem Cable): For connecting the 168-7721 to a modem which transfers data over telephone lines to a personal computer.
4
1U-7445
NiCad (Nickel Cadmium) Rechargeable Battery: (size AA) 1 per package.
5
1U-9533
Alkaline Battery: Non-rechargeable battery (size AA) 96 per package.
6
156-1077
Power Inverter: For powering the 1687721 from 12VDC and includes battery cables and a cigarette lighter.
7
9U-6175
Soft Protective Case: For protecting the 168-7721 during use.
—
—
Custom Track Service (CTS) software program for transferring stored measurements from the 168-7721 to an IBM PC, or compatible, computer for storage or printing. Also required when a modem is used.
—
—
Additional Service Replacement Part (not shown).
—
4C-5490
Couplant Holder: The service replacement for the holder that stores the 9U-7981 Couplant container.
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 . . . . . . . . -40°C to 60°C (-40°F to 140°F) With Alkaline Batteries Installed . . . -40°C to 50°C (less than 6 months) (-40°F to 125°F)
Power Supplied By 5 NiCad (Nickel Cadmium), rechargeable batteries (size AA) or non-rechargeable 1U-9533 Alkaline Batteries.
With NiCad Batteries Installed . . . . -20°C to 45°C (less than 6 months) (-4°F to 113°F)
NOTE: The five AA batteries are accessed by removing the Indicator III’s 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 III’s backlight OFF and beeper ON). NiCad Rechargeable . . . . . . . . . . . . . . . 19 Hours Alkaline Non-rechargeable . . . . . . . . . . . 47 Hours
168-7722 Ultrasonic Probe Specifications
Approximate Battery Life (with Indicator III’s 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 . . -18°C to 150°C (0°F to 300°F) 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 . . . . . . . . . . -18°C to 60°C (O°F to 140°F)
7
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.
1
9U-7981
Couplant Stored in pump-type dispenser. A small amount of couplant must be applied to the sensing end of the 168-7722 Ultrasonic Probe, before measuring, to couple ultrasonic sound into the material being measured.
2
4C-5490
Holder Used to hold the 9U-7981 Couplant Dispenser
3
—
4
RS232
5
—
6
Probe
7
—
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 VAC Operating Temperature Range . . . . 10°C to 26.7°C (50°F to 80°F) Over Temperature Protection . . . . When the power inverters internal heat sinks reach 65.5°C (150°F), the inverter will automatically shut down. The inverter may be “restarted” by first disconnecting the inverter and allowing 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 beeper’s 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 disk’s 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.
9
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 display’s 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.
1
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.
2
MACH (CLEAR)
MACH Display After Clearing Machine Memory.
18
List of Undercarriage Storage LOC(ation) Displays Loc. 1 2 3
Display
4
MODEL SERIAL NUMBER DATE MM/DD/YYYY DATE DD/MM/YYYY HOURS
5
HRS. / WEEK
6
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 machine’s 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
2
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:
2
• 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
2
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.
2
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.
2
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 Mode’s 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 III’s 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 III’s 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 machine’s 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 III’s 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/µSEC or (.231 IN/µSEC), as shown in Step 2.
Ultrasonic Velocity is the speed in Millimeters per microsecond (MM/µSEC) or inches per microsecond (IN/µSEC) 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 µEC MM/µ µSEC) (IN/µ
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/µSEC.
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/µSEC. 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 III’s 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
1
(CLEAR)
LOCation DISPLAYS
1
MACH
(CLEAR)
ON OFF
FACTORY RESET
TYPICAL DISPLAYS
VALUE KEY
MODEL –––––––––
1
ARROW KEYS
ARROW KEYS
2
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 ––––––––––––––––
1
MODEL D––––––––
"9" KEY
3
MACH
(CLEAR)
4
MACH
(CLEAR)
5
MACH
1 DATE
MM/DD/YYYY 01 / 01 / 1999
1
MODEL D –––––––
1
HOURS ––––––
1
MODEL D9– – – – – – –
1
HRS. / WEEK –––
(CLEAR)
1
MILES ––––––
1
MILES / WEEK ––––
SAVE KEY
1
MODEL D9
1 JOB SITE –––––––––––––––
63
MACH
(CLEAR)
1
64
MACH
(CLEAR)
1
1
IMPACT COND 2 MODERATE
ABRASIVE COND 2 MODERATE
VALUE KEY
ARROW KEYS
1 3
IMPACT COND HIGH
1
IMPACT COND LOW
1
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
1
PACKING COND 2 MODERATE
1
ARROW KEYS
1
1
ARROW KEYS
1
R IDLER SONIC 0.00 0.00IN
TRACK SAG 0.00IN
1
L CAR. ROLL 1 0.00 0.00IN
L DRY JOINTS ––
1
L CAR. ROLL 2 0.00 0.00IN
1
L CAR. ROLL 3 0.00 0.00IN
BUSHING ALLOW 2 GREATER
L 0.00
1
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 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
1
VALUE KEY
1 0.00
L SHOE 0.00IN
ARROW KEYS
1 3
BUSHING TOOL DEPTH GAUGE
1
1 1
SHOE TOOL ULTRASONIC
1
1
F IDLER DEPTH 0.00 0.00IN
1
F IDLER SONIC 0.00 0.00IN
1
1
0730-31
TO L ROLLER 7 DISPLAY
35
LOCation Display Map (cont’d) FROM L ROLLER 6 DISPLAY
1
L ROLLER 7 0.00IN
0.00
ARROW KEYS
1
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
1
R IDLER DEPTH 0.00 0.00IN
1
R IDLER SONIC 0.00 0.00IN
1
1
R CAR. ROLL 1 0.00 0.00IN
1
SPROCKET –––––––
1
R CAR. ROLL 2 0.00 0.00IN
1
1 R TRACK SAG 0.00 0.00IN
1
R CAR. ROLL 3 0.00 0.00IN
1 NOTES LINE 1 ––––––––––––––––
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
1
0.00
R ROLLER 5 0.00IN
1
0.00
L ROLLER 8 0.00IN
1
0.00
L ROLLER 9 0.00IN
1
0.00
L ROLLER 10 0.00IN
1
0.00
1 1
ROLLER TOOL ULTRASONIC
1
L
1
1
1
R DRY JOINTS 21
R LINK 0.00IN
1
1 R BUSHING INT 0.00 0.00IN
1
1 R BUSHING EXT 0.00 0.00IN
1
1
1
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
R
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 . . <20°F 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 . . . . . . . . . . . . >220°F pH: 7.35 to 7.9
Store between 20°F and 120°F. 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
[email protected] 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 “
[email protected]"
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
[email protected]
©2005 Caterpillar All Rights Reserved
NEHS0730-02 Printed in U.S.A.
