415-4055 Ultrasonic Wear Indicator IV Group{0787, 7000} Caterpillar

Caterpillar Products: All

Introduction

European Union Compliant, CE Marked

Important Safety Information

Illustration 1	g02139237
Think Safety

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

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

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

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

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Literature Information

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

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

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

Safety Section

The Safety Section lists basic safety precautions.

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

General Information Section

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

Operation Section

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

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

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

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

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2	g02166423
Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

General Information Section

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Introduction

The 415-4055 Ultrasonic Wear Indicator IV Group provides a fast accurate method of measuring track-type machine undercarriage wear. By placing a probe on the part to be measured, the Ultrasonic Wear Indicator IV will show the part thickness on the graphical 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.

The Custom Track Service CTSi: personal computer program supports the Ultrasonic Wear Indicator IV. When used with the Ultrasonic Wear Indicator IV, CTSi provides a professional alternative for the mechanical CTS tool kit. Additionally, the new CTSi program will be able to send wear table information to the Ultrasonic Wear Indicator IV allowing users to see percent worn Calculations immediately as they are measured. The Ultrasonic Wear Indicator IV measures the part 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 IV converts the time into a thickness value and displays it. 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 415-4053 Soft Case for the Indicator IV.

Other Uses for the Indicator IV

Quick and accurate, nondestructive thickness measuring of track beds, truck bed liners, bulldozer blades, bucket base edges, and bucket cutting edges.

Benefits and Features of the Ultrasonic Wear Indicator IV

For many years, CTS inspectors have used the mechanical CTS kit, then the later Ultrasonic Wear Indicator line of tools to measure undercarriage wear. While these tools worked well, the new Ultrasonic Wear Indicator IV has many benefits over the previous measurement methods. These features include:

• New design uses state-of-the art electronics for even higher accuracy and reliability than previous generations.

• Easy battery access; Unscrew the calibration disk at the top of the Indicator IV to access the three AA batteries.

• Larger graphical backlit Liquid Crystal Display can be turned On or OFF, or even have its colors inverted for easy viewing day or night, inside or out.

• Power Level Monitor shows estimated battery power remaining at all times.

• Built-in multiple language capability with English, Portuguese, French, Spanish, and German languages. There are no program modules or reflashing needed to switch languages.

• 415-4051 Ultrasonic Indicator IV Group includes an updated probe with a thinner housing allowing easier access in tight spaces, and better strain relief for the internal wires in the cable.

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

• Uses three Alkaline or rechargeable AA batteries (no battery pack).

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

General Measurement Benefits

• High accuracy measurements - Digital display of thickness is accurate to 0.1 mm (.01 inch).

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

• Calibrated for under carriage steel.

• 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.

Undercarriage Measurement Benefits

• Less time cleaning parts. Only a small surface on the wear area must be cleaned. On bushings, the back side, between the bushing and shoe, does not require cleaning.

• Measures track idler center flange thickness.

• Eliminates errors caused by dirt packed around parts.

• Accurately measures bushing wear after turning.

• Stores information from 100 machines.

• All CTS inspectors measure with the same accuracy because the CTSi computer program directly calculates percent wear and projected life.

• Works with the updated CTSi program to download wear tables of machines to be measured, then displays the percent worn calculation immediately on the screen.

Ultrasonic Wear Indicator IV Groups

Illustration 4	g03328236

423-0478 CTS Group (Refer to Chart A for item identification)

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425-4055 Ultrasonic Wear Indicator IV Group (Refer to Chart B for item identification)

Storage of Conventional Tools

(Storage for Conventional CTS Tools in 4C-3975 Carrying Case - Refer to Chart C for item identification.)

Conventional CTS tools can be stored with the 415-4055 Ultrasonic Wear Indicator IV Group . Because some undercarriage components cannot be measured with the 415-4051 Ultrasonic Wear Indicator IV , provisions have been made for storing the required conventional CTS tools in the carrying case. These tools are not provided with the 415-4055 Group but do come in the 423-0478 CTS Group , and may be ordered separately.

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

Table 1

Chart A
423-0478 CTS Group
Item No.	Part No.	Description
1	415-4055	Ultrasonic Wear Indicator IV Group
2	8H-8580	Scraper For cleaning undercarriage components
3	5P-3920	Steel Rule 300 mm (12 inch)
4	4S-9405	12" Caliper
5	5P-3277	Tape Measure 3mm (10 ft) For pitch, sag, and sprocket measurement
6	423-0483	Depth Gauge Replaces older 6V-9410
7	9U-7881	Ultrasonic Couplant x2

Table 2

Chart B
415-4055 Ultrasonic Wear Indicator Group
Item	Part No.	Description
1	415-4051	Ultrasonic Wear Indicator IV Included: -Four protective caps for RS232 connector -USB to serial adapter -NEHS0730 Ultrasonic Wear Indicator IV Group Tool Operating Manual
2	415-4052	Ultrasonic Probe
3	415-4053	Soft Case with Couplant Holder
4	415-4054	Foam Insert Set
5	267-6532	Paper Towels (18 sheets)
6	4C-3975	Case
7	425-6888 Also included with 415-4051	Serial Communication Cable (Lemo to DB-9)

Table 3

Chart C Storage Locations
Item	Part No.	Description
1	PEKP9400	Custom Track Service Handbook Fits under Indicator IV

Optional Items

Note: Three AA batteries are required to power the 415-4051 Ultrasonic Wear Indicator IV .

Table 4

Item	Part No.	Description
		Custom Track Service (CTSi) Software program for transferring stored measurements from the 415-4051 to an IBM PC, or compatible computer for storage or printing.

Specifications

Illustration 6	g03328253

415-4055 Ultrasonic Wear Indicator IV Group

Table 5

Power Supply	3 AA rechargeable or non-rechargeable batteries Note: The three AA batteries are accessed by removing the Indicator IV calibration disk on the top of the tool. See "Replacing the Internal Rechargeable Batteries" section
Approximate Battery Life
With Indicator IV backlight OFF and beeper ON
NiCad Rechargeable	100 Hours
Alkaline Non-rechargeable	150 Hours
With Indicator IV backlight ON and beeper ON
Indicator IV shuts down	2.8V
Measurement Range (Steel)	1.27 mm (0.50 inch ) to 254 mm (10.0 inch)
Measuring Resolution	± 0.1 mm (0.01 inch)
Measurement Accuracy	± 0.1 mm (0.01 inch)
Operating Temperature	-10° to 60° C (-14° to 140° F)
Storage Temperature without batteries installed	-40° C to 60° C (-40° to 125° F)
Storage Temperature with alkaline batteries installed less than 6 months	-40° C to 50° C (-40° to 125° F)
With rechargeable batteries installed less than 6 months	-20° C to 45° C (-4° to 113° F)
Memory Size
Non-Volatile Random Access Memory (RAM)	4 Megabytes
RS232 Specifications	115,200 Baud
Display
1/8 inch VGA grayscale display	240 x 160 pixels
Viewable Area	62 x 45.7 mm (2.4 x 1.8 inch)
External Dimensions
4C-3975 Carrying Case	394 x 312 x 140 mm (15.5 x 12.25 x 5.5 inch)
Weight
415-4055 Group	3 kg (6.75 lb)
415-4051 Group Indicator IV	0.4 kg (0.84 lb)
415-4052 Probe	0.113 kg (.25 lb)

168-7722 Ultrasonic Probe Specifications

Table 6

Probe Type	Dual Element 7.5 MHz special application probe
Probe Size
Measuring Surface Diameter	10 mm (.394 in)
Length	44 mm (1.73 in)
Diameter	16 mm (.63 in)
Allowable Surface Temperature	18° to 150° C (0° to 300° F)
Cable Length	1524 mm (60 in)
Includes Certificate of Conformity

Connections to the 415-4051

Table 7

Item No.	Part No.	Description
1	9U-7891 Couplant	Stored in pump-type dispenser. A small amount of couplant must be applied to the sensing end of the 415-4052 Ultrasonic Probe before measuring to couple ultrasonic sound into the material being measured.
2	415-4053	Soft Case with Holder
3		Steel Calibration Disk - The disk is used to check the accuracy of the wear indicator and recalibrate the wear indicator, if necessary. For additional information, refer to Calibrating the Ultrasonic Wear Indicator IV in this manual
4	RS232 Connector (shown without protective cap installed)	Used to connect 425-6888 Cable Assembly RS232 (Lemo) to PC or USB adapter. These cables can be used to transfer stored undercarriage data from the 415-4051 to a personal computer. Refer to Optional items in this manual for specific function and software program requirements.
5		USB to Serial Adapter: used to connect the Lemo RS-232 cable to PC without Serial Ports. Other adapters may be used but this adapter has been validated to work with the 415-4051.
6		Probe Connector: used to install the 415-4052 or 168-7722 Ultrasonic Probe

415-4051 Indicator IV Description

Description

Table 8

Abbreviations and Descriptions used on Front Panel, Back Label and Key Pad
1	Probe Zero 0.41 or 0.42 in (10.5 mm)	Describes the metal calibration disk thickness measured in millimeter and inches during probe calibration (metal calibration disk is located on top panel).
2	Menu	Cycle through the menu screens (Calibrate Probe, Measurement Only, and Preferences).
3	CLR	Clears and backspaces a character or clears machines in the Machine Mode.
4	Backlight Icon	Manually turns backlight On or Off while the tool backlight preference has been set to Off or Auto. This button has no effect if the backlight preference is set to On or Inver. The backlight can be set to On, Off, Automatic, or Inverted in the Preferences Menu.
5	Save	Saves the current measurement, entry, or value and advances to the next field.
6	UP ARROW Icon	Scroll up menu items or increment numeric values in entry fields.
7	ESC	Escapes from an entry field without saving
8	Left Arrow Icon	Scrolls left through selection fields, numeric entry fields, and the virtual keyboard.
9	Enter	Opens a field for the manual entry of text or numbers. For text fields this opens the virtual keyboard.
10	Multi Mode	Cycles the display through the Machine Selection Mode and the Inspection Mode. Different Inspection Modes (Full, Partial, Custom, Ultrasonic and Partial Ultrasonic) are available and can be selected from the Preferences Menu.
11	Right Arrow Icon	Scrolls through selection fields, numeric entry fields, and the virtual keyboard.
12	Down Arrow Icon	Scroll down menu Items or decrement numeric values in entry fields.
13	On/Off	Turns Indicator IV ON or OFF The Indicator IV has a feature to automatically turn the tool OFF after a time period if not in use. This function can be disabled or the duration before shut off changed in the Preferences menu. Refer to Preferences section of this manual.

Replacing the Internal Batteries

The 415-4051 Ultrasonic Wear Indicator IV is supplied with three Alkaline batteries (size AA). These can be replaced with new 1U-7445 Rechargeable Batteries or 1U-9533 Alkaline (Non-rechargeable) Batteries .

Note: The internal batteries can be removed indefinitely and the internal memory values will not be affected.

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Illustration 7	g03397301

1. Unscrew the Calibration Disk (1) from top panel (2) .

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2. Remove Calibration Disk (1) .

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

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Illustration 10	g03328261

4. To install the new batteries, the batteries must be placed in the tool with the correct polarity. The (+) post of the battery should point into the tool as shown in the Illustration and as shown by the battery orientation figure on the back label of the tool.

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Illustration 11	g03397301
(1) Calibration Disk (2) Top Panel

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Illustration 12	g03397880

5. After inserting the batteries, install the Calibration Disk (1) and hand tighten, taking care not to damage the O-ring (4) .

Care and Cleaning of the 415-4051 Indicator IV

The 415-4051 Ultrasonic Wear Indicator IV 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. The case is extruded aluminum with gasket seals and is water and dust resistant. It is not completely waterproof however, and the instrument can be damaged if water is allowed to enter the case. If moisture does enter the case, the Indicator IV should be allowed to dry out. Keep the Indicator IV stored in the carrying case when not in use.

Removing the 9U-7981 Couplant Residue

When taking measurements, all excess 9U-7981 Couplant residue should be removed from the probe, Indicator IV, and case with paper towels before the residue dries. The couplant is water soluble and a damp cloth can be used to remove any residue that has dried.

Cleaning the Case and Front Panel Key Pad

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NOTICE
Do not use aromatic hydrocarbons or chlorinated solvents for cleaning. These chemicals will react with the plastics used in the keypad and display and cause damage.

Care of Connectors

The RS232 and PROBE connectors on the ends of the Indicator IV must be kept clean. Allowing dirt to enter the contacts can cause interference and keep the mating connectors from plugging in or making proper contact. During use, the PROBE connector is protected by the probe cable connector. Leave the probe connected during storage so dirt does not enter. The RS232 connector is shipped with a plastic cap in it. Keep this cap in place at all times when this connector is not being used. Extra plastic caps are included with the group.

Operating Instructions for 415-4051 Indicator IV

Turn ON the Indicator IV

1. Press and release the ON/OFF key.

2. The display will show the Splash screen display for a short time then automatically change to the last screen viewed on the tool (Probe Calibration by default when first received).

Calibrating the Indicator IV and Probe

Before taking measurements, the accuracy of the Indicator IV and the probe should be checked and the Indicator IV and probe recalibrated, if needed. This procedure should be performed at the start of each day and any time the accuracy is in question to ensure the readings taken will be accurate. Once the Indicator IV and probe are calibrated with this procedure, it will ONLY be accurate for measuring undercarriage steel or steel of a similar type.

There are two calibration methods used by the indicator IV; Automatic and Manual.

By default, Automatic is selected. Automatic calibration is the easiest and fastest method but does not check the tool against the calibration disk. Automatic calibration checks and adjusts the "zero" thickness measurement of the probe. Manual calibration requires the use of the calibration disk and can be used to verify the calibration of the tool. Manual calibration checks and adjusts the probe against a known "span" thickness. In some cases it is possible for a probe to give incorrect readings after just a manual or automatic calibration. To correct this situation, if it should ever be encountered, the manufacturer recommends first doing a manual calibration, changing the calibration mode in the Preferences to Automatic, and recalibrating. This will adjust both the zero and span calibrations and can remove most calibration problems should they occur. It should not be necessary to do both calibrations under normal operations.

Automatic Probe Calibration

To calibrate the Indicator and Probe using the Automatic Calibration method:

1. Insure the Indicator's "Zero Probe" selection is set to AUTO in the Preferences Mode. Refer to the Changing Preferences Settings in this manual.

2. Press and release the MODE key until the Indicator IV is in the Calibrate Probe menu screen.

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Illustration 13	g03328276

3. Insure the probe is properly installed in the connector at the top of the Indicator IV.

4. Clear any couplant from the probe.

   Note: Failure to clear the couplant from the probe can cause improper calibration.

5. Hold the probe in open air. DO NOT use the probe calibration disk for automatic calibrations.

6. Press and release the ENTER key to perform the Automatic calibration. A screen stating "Performing Auto Probe Zero" will briefly display.

7. The tool will then automatically return to the Automatic Probe Calibration screen.

Manual Probe Calibration

A metal calibration disk, (A) is used to check the accuracy and manually calibrate the Indicator IV probe. To calibrate the Indicator and Probe using the Manual Calibration Method:

1. Make sure that the Indicator's "Zero Probe" selection is set to MANUAL in the Preferences Mode. Refer to the Changing Preferences Settings in this manual.

2. Press and release the MODE key until the Indicator IV is in the Calibrate Probe menu screen.

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Illustration 14	g03328319

3. Make sure that the probe is properly installed in the connector at the top of the Indicator IV.

4. Apply a small amount of couplant to the probe.

5. Securely press the probe against the probe calibration disk.

6. A measurement reading will appear at the bottom of the screen. Wait for a steady reading. The correct reading should be 10.5 mm (0.41 inch or 0.42 inch). If the tool reads correctly, no calibration is needed. If the reading is not correct, then continue with the following step.

7. Press and release the ENTER key to perform the Manual calibration.

8. A screen stating "Performing Manual Probe Zero" will briefly display.

9. The tool will then automatically return to the Manual Probe Calibration screen.

Basic Measurement Procedure (Measurement Only)

1. The Indicator IV MUST be calibrated before any measurements are taken. Refer to Calibrating the Ultrasonic Wear Indicator IV section.

2. After calibration, use the MENU key to go to the MEASURE ONLY Mode screen.

Illustration 15	g03328340

The MEASURE ONLY screen has large display digits that make it easy to read the measured value. This screen does not allow the storage of measurements however. This mode is recommended when using the Indicator IV to measure non-undercarriage components.

Undercarriage Measurement Procedure

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

1. The Indicator IV MUST be calibrated before any measurements are taken. Refer to Calibrating the Ultrasonic Wear Indicator IV section.

2. After calibration, use the Multi Mode key to enter the Machine Mode. The Machine Mode is used to enter or select machine information such as model, serial number, and location.

Illustration 16	g03328345

Clearing the Memory

If a clear or unused machine entry field cannot be located, any one or all machines can be cleared.

1. To CLEAR a single machine entry, use the Up and Down arrow keys to select the machine you want to clear. Then press the CLR key (Machine 2 in this example).

2. The default selection is to clear the currently selected machine entry (Clear machine 2 in this example), press the Enter Key to select it.

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Illustration 17	g03328734

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Illustration 18	g03328773

3. A confirmation screen will appear asking if you are sure that you wish to clear the machine. Press the CLR key to clear the machine or the ESC key to cancel.

   Note: When a machine memory is cleared, the data that was in the memory for that machine number will be lost and cannot be retrieved.

4. To clear all machines, first press the CLR key in any Machine field. In the next screen use the Down Arrow key to select the CLEAR ALL MACHINES entry then press ENTER. You will be asked to confirm that you intend to clear all machine fields. Press the CLR key again to confirm and clear the fields or the ESC key to cancel. If you continue clearing the fields, a message "Clearing XX" will appear near the bottom of the screen and count up to 100 as it clears each field.

Illustration 19	g03328802

Illustration 20	g03328807

Using Inspection Modes of Operation

To store ultrasonic measurements and input information about the machine being measured, the indicator IV must be in one of the Inspection modes of operation. To change to an inspection mode from the machine mode, use the Up and Down arrow keys to select the desired machine from the Machine Mode list. Press the Multi Mode key to change to the Inspection mode. This key always changes the display to the other mode of operation.

Note: Use the Multi Mode key to go to the Inspection mode for the machine entry selected. Using the Enter Key will not select it.

Note: The Inspection mode that will be displayed is determined by the preferences set in the Preferences Menu.

The different inspection types include: Full, Partial, Custom, Ultrasonic, and Partial Ultrasonic. See the Inspection Modes section of this manual to see what fields each of these contain. Once in the Inspection mode, the different undercarriage storage locations shown in the "List of Undercarriage Storage Locations Displays by Inspection Mode" 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.

List of Undercarriage Storage Location Fields

Note: The Preferences Menu is used to change how the Date (location 3), the Forward Odometer (location 6), the Reverse Odometer (location 7), the Total Odometer (location 8), and the Odometer Units (location 9) are displayed.

Table 9

Location	Display	Notes
1	MODEL	The machine model number
2	SERIAL NUMBER	The machine serial number
3	DATE	The date by month, day, year or by day, month, year
4	HOUR METER READING	The service hour meter reading on the machine
5	HOURS PER WEEK	The number of hours the machine works per week
6	FORWARD ODOMETER	The number of miles, kilometers, or hours on the machine operating in the forward direction
7	REVERSE ODOMETER	The number of miles, kilometers, or hours on the machine operating in the reverse direction
8	TOTAL ODOMETER	The total number of miles, kilometers, or hours on the machine operating in both forward and reverse direction. This field is calculated by the CTS computer program automatically, so it is not necessary to enter it if CTS is being used.
9	ODOMETER UNITS	The measurement units on the machine odometer in miles, kilometers, or hours.
10	JOB SITE	The location of the machine
11	IMPACT CONDITIONS	The underfoot conditions at the job site - select from MODERATE, HIGH, LOW
12	ABRASIVE CONDITIONS	The underfoot conditions at the job site - select from MODERATE, HIGH, LOW
13	MOISTURE CONDITIONS	The underfoot conditions at the job site - select from MODERATE, HIGH, LOW
14	PACKING CONDITIONS	The underfoot conditions at the job site - select from MODERATE, HIGH, LOW
15	BUSHING ALLOWABLE WEAR	Bushing allowable wear for this machine - select from GREATER and LESSER
16	LINK ALLOWABLE WEAR	Link allowable wear for this machine - select from GREATER and LESSER
17	LEFT TRACK SAG	The track sag on the left side LEFT FRAME EXTENSION Frame extension on the left side
18	LEFT DRY JOINTS	The number of dry joints on the left side LINK PART NUMBER The part number on the link
19	LEFT LINK	Left side link measurement
20	LEFT BUSHING INTERNAL	Left bushing internal wear
21	BUSHING TOOL	Measuring tool used on bushings - select from ULTRASONIC, CALIPER, DEPTH GAUGE
22	LEFT BUSHING EXTERNAL	Left bushing external wear
23	SHOE TOOL	Measurement tool used on Shoes – select from ULTRASONIC, DEPTH GAUGE
24	LEFT SHOE	Left slideshow measurement
25	LEFT FRONT IDLER DEPTH	Front idler depth gauge measurement
26	LEFT FRONT IDLER SONIC	Front idler ultrasonic measurement
27	LEFT REAR IDLER DEPTH	Rear idler depth gauge measurement
28	LEFT REAR IDLER SONIC	Rear idler ultrasonic measurement
29	CARRIER ROLLER TOOL	Measuring tool used on carrier rollers – select from CALIPER AND ULTRASONIC. The tool will default to the last tool used.
30	LEFT CARRIER ROLLER	1 Left front carrier roller measurement
31	LEFT CARRIER ROLLER	2 Left carrier roller number 2 measurement
32	LEFT CARRIER ROLLER	3 Left carrier roller number 3 measurement ULTRASONIC, CALIPER
33	ROLLER TOOL	Measuring tool used on track rollers - select from ultrasonic, Caliper, Depth gauge
34	LEFT TRACK ROLLER	1 Left front track roller number measurement
35	LEFT TRACK ROLLER	2 Left track roller number 2 measurement
36	LEFT TRACK ROLLER	3 Left track roller number 3 measurement
37	LEFT TRACK ROLLER	4 Left track roller number 4 measurement
38	LEFT TRACK ROLLER	5 Left track roller number 5 measurement
39	LEFT TRACK ROLLER	6 Left track roller number 6 measurement
40	LEFT TRACK ROLLER	7 Left track roller number 7 measurement
41	LEFT TRACK ROLLER	8 Left track roller number 8 measurement
42	LEFT TRACK ROLLER	9 Left track roller number 9 measurement
43	LEFT TRACK ROLLER	9 Left track roller number 9 measurement
44	LEFT SPROCKET MEASUREMENT	Left sprocket measurement
45	LEFT SPROCKET CONDITION	The condition of the left sprocket – select from EXCELLENT, GOOD, FAIR, POOR
46	RIGHT TRACK SAG	The track sag on the right side
47	RIGHT DRY JOINTS	The number of dry joints on the right side
48	RIGHT LINK	Right side link measurement
49	RIGHT BUSHING INTERNAL	Right side bushing internal wear
50	RIGHT BUSHING EXTERNAL	Right bushing external wear
51	RIGHT SHOE	Right side shoe measurement
52	RIGHT FRONT IDLER DEPTH	Front idler depth gauge measurement
53	RIGHT FRONT IDLER SONIC	Front idler ultrasonic measurement
54	RIGHT REAR IDLER DEPTH	Rear idler depth gauge measurement
55	RIGHT REAR IDLER SONIC	Rear idler ultrasonic measurement
56	RIGHT CARRIER ROLLER	1 Right front carrier roller measurement
57	RIGHT CARRIER ROLLER	2 Right carrier roller number 2 measurement
58	RIGHT CARRIER ROLLER	3 Right carrier roller number 3 measurement
59	RIGHT TRACK ROLLER	1 Right front track roller number measurement
60	RIGHT TRACK ROLLER	2 Right track roller number 2 measurement
61	RIGHT TRACK ROLLER	3 Right track roller number 3 measurement
62	RIGHT TRACK ROLLER 4	4 Right track roller number 4 measurement
63	RIGHT TRACK ROLLER 5	Right track roller number 5 measurement
64	RIGHT TRACK ROLLER 6	Right track roller number 6 measurement
65	RIGHT TRACK ROLLER 7	Right track roller number 7 measurement
66	RIGHT TRACK ROLLER 8	Right track roller number 8 measurement
67	RIGHT TRACK ROLLER 9	Right track roller number 9 measurement
68	RIGHT TRACK ROLLER 10	Right track roller number 10 measurement
69	RIGHT SPROCKET MEASUREMENT	Right sprocket measurement
70	RIGHT SPROCKET CONDITION	The condition of the left sprocket – select from EXCELLENT, GOOD, FAIR, POOR

Illustration 21	g03328825

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 when blank field is displayed or text already shown can be changed.

Entering information into the Indicator IV

Illustration 22	g03329795

If the memory contains a Model number, it will always be shown on the display. If it does not contain a Model number, a blank field will show where the number should be entered. To enter the Model, press the ENTER key and the virtual keyboard will appear. The first text location will become a dark box with the currently selected character showing in the box. Whenever virtual keyboard is on the display, numbers or alphabetical characters may be entered using the keys on the front panel.

Entering Data into Text fields on the Indicator IV

To enter a character use the Up, Down, Left, and Right arrow keys to select the desired character. Press the ENTER key to select the currently highlighted character. Press the CLR key to backspace. Pressing the SAVE key saves the text and returns to the previous screen. Pressing the ESC key returns to the previous screen without saving the current text. After SAVE is pressed, the Indicator IV will advance the display to the next location display, which is the SERIAL NUMBER. To enter the serial (product identification) number into the SERIAL NUMBER display, follow the same procedure as used for the Model location. Up to 12 numbers or letters in any combination can be entered as the serial number on the blanks provided. The same procedure will be used for entering any text or note field.

Entering Data in Numeric fields on the Indicator IV

A different method of entering data is used for Numeric Fields such as:

• DATE

• HOURS

• HOURS PER WEEK

• MILES or KM

• MILES PER WEEK or KM PER WEEK

Illustration 23	g03329802

To enter data into a Numeric Field or Location, select the field or location using the arrow keys, then press the ENTER key. A numeric entry screen will appear. When in a numeric entry screen, press the Up and Down arrows to increase or decrease the value of the currently highlighted digit. Press the Left or Right arrows to highlight a different digit. Press the ENTER key to save the current digit value and move right to the next digit. The CLR key deletes the current digit. The current number in the location and advance to the next location.

Changing Locations with a List of Selections

The Location displays for under foot conditions (IMPACT CONDITIONS), bushing allowable wear (BUSHING ALLOWABLE WEAR), and other locations have words from a pre-selected list of options in them.

Illustration 24	g03329826

Illustration 25	g03329827

Illustration 26	g03329829

On these displays, several words are available. To view the other words available, press the Left or Right arrow keys. The other selections will appear, as shown in the previous examples. To select and store the desired word in the memory, leave it on the display and press the up or down arrow key (or the SAVE key) to move on to the next location.

Measuring Track Sag

The first display for a measurement is LEFT TRACK SAG. This measurement cannot be taken with the Indicator IV. It must be taken according to the instructions in the CTS handbook with a tape measure and manually entered into the Indicator IV memory.

1. To enter this measurement at the LEFT TRACK SAG location, press the ENTER key.

2. A numeric entry screen will appear allowing the measurement to be entered. Refer to the topic Entering Information into the Ultrasonic Wear Indicator IV section.

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

Taking Ultrasonic Measurements

The first measurement location can 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. 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.

2. The measurement will appear on the display in the Upper right-hand corner.

3. An indication of proper coupling of the probe is shown by bars appearing in the upper left corner. Also, a beeping sound will be heard, the backlight will turn on, and the front LED will light (if not turned OFF using the Preferences menu) to indicate good coupling.

4. When you are satisfied a good value is on the display, remove the probe and that value will remain in the upper right corner.

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. The next location will automatically be selected on the display after saving a measurement.

Note: While taking an ultrasonic measurement, once satisfied of a good measurement, press the SAVE key before removing the probe. This prevents slight shifts in the measurement caused when removing the probe.

Tool Displays

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:

Illustration 27	g03329847

Illustration 28	g03329849

Pressing the Left or Right Arrow keys will select the tool used to make the measurement. Press the Down arrow key or SAVE 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.

When finished with the measurements, advance to the next machine by pressing Multi Mode key to go to the Machine Mode screen and select the next Machine.

Measurement Operating Tips

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

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 IV. 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 in the Measurement Only option in the Menu. 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.

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 of the surface to find the smallest, or most worn measurement.

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

Undercarriage Measurement Techniques

Track Links

Illustration 29	g03329858

1. Measure distance from tread surface to bushing bore.

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

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

Track Shoes

Illustration 30	g03329872

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

Show/hide table



Illustration 31	g03329875

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

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

4. On regrouped shoes, it may be necessary to use 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.

Track Bushing

Illustration 32	g03329896

1. Measure the wall thickness.

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.

Idler

Illustration 33	g03329929

1. Measure the center flange thickness only on fabricated idlers. Determine center flange wear from the idler wear charts in the CTS Handbook.

2. Use conventional depth gauge to measure wear on the tread surface.

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

Carrier Roller

Three Piece Rims

Illustration 34	g03329960

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.

Illustration 35	g03329967

Illustration 36	g03329969

Note: The Ultrasonic Wear Indicator IV will not measure cast iron rollers. Some D3, D4, D5, and D6 Tractors or 225 Excavator carrier rollers are cast iron.

Track Roller

Illustration 37	g03330001

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.

   On low sprocket Track-Type Tractors, earlier type Loader 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.

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.

Competitive Parts

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

Measuring the Thickness of Parts Other than Undercarriage

In addition to measuring undercarriage wear, the Ultrasonic Wear Indicator IV can be used to measure steel part thickness without changing any settings. This is simple to do because the wear indicator has a MEASUREMENT ONLY operation accessible by cycling through the Menu options. This allows a user to take readings without needing to navigate the machine or inspection screens. Examples where this may be used are to check the wall thickness of aBulldozer blade, Bucket base edge and Scraper bowl

1. Install 415-4052 or 168-7722 probe, and calibrate the Indicator IV and probe. When taking measurements, the 9U-7981 Couplant must be applied to the sensing end of the probe before measuring.

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 the center of the display. Whenever the probe is properly coupled, five bars will be shown in the upper left corner on the display. Also, a steady beeping sound will be heard. The backlight will illuminate, and the front LED will light (if not turned OFF in the Preferences Menu). When the probe is removed from the material, the last reading will remain on the display.

3. To check the accuracy of the reading, measure a piece of the same type of material of known thickness.

Summary Mode

The summary mode allows a user to review measurements made for the current machine selected in the machine mode. To view this mode, press the MULTI MODE button until the MODE summary screen displays. Press the UP and DOWN keys to navigate through the entries. Pressing the ENTER key on an entry allows the user to modify that valve.

Transferring the Memory Values to or From a Computer

The information contained (saved) in the Indicator IV memory may be transferred to a personal computer for storage or printing using the Custom Track Service (CTSi) computer program. When transferring machine data from a personal computer using the Custom Track Service (CTSi) program, the Indicator IV does not clear all 100 machines before transferring new machine data from the PC. The CLEAR ALL MACHINES function may be used to manually clear all 100 machines before you transfer.

Preferences Menu

The Preferences Menu is a special menu to change specific functions for the wear indicator. Enter the Preferences Menu by pressing and releasing the MENU key until the screen displays the Preferences Menu screen. The Preferences Menu contains these functions in this order: Inspection Type, Backlight, Contrast, Zero Probe, Gain, Beeper, Lights, Language, Date Format, Units, Odometer Units, Decimal Separator, Shut off Time, Edit Custom Inspection, Reset Custom Inspection, and About UWI IV. Press the up or down arrow to scroll forward or backwards through the Preferences Menu.

Inspection Type

This function is used to select which locations are displayed in the Inspection mode screen. Users who do not use all of the available locations may use the alternate inspection modes to reduce the amount of scrolling needed to complete an inspection. The available options are, Full, Partial, Custom, Ultrasonic, and Partial Ultrasonic.

Full shows all of the locations. Partial shows a smaller list of locations that are more commonly used. Custom shows those locations selected by the user from the Edit Custom Inspection setting in the Preferences Menu. Ultrasonic shows only those locations that can be measured using the Ultrasonic Wear Indicator IV. Partial Ultrasonic shows only the most commonly used Ultrasonic measurement locations.

Backlight

This function controls the display backlight of the Indicator. Available selections include, Auto, Invert, Off and On. Auto leaves off the backlight until the Indicator is used to make a measurement, then automatically illuminates when the probe has a strong couple to the measured material. Invert causes the display to reverse the dark and light areas and turns on the backlight. Invert is useful when making measurements in strong light. Off turns off the backlight. On turns on the backlight.

Note: While either Auto or OFF are selected, the backlight key will toggle the backlight on or off. But while either Invert or On are selected, the backlight key has not effect.

Contrast

This adjusts the contrast of the display. Selections range from 1 (lightest) to 20 (darkest).

Zero Probe

This selection determines the type of calibration method used by the Calibrate Probe Menu. Either Auto or Manual can be selected. Refer to the Calibrating the Indicator IV and probe section of this manual for the differences between these modes.

Gain

This function controls the gain used by the sensing element of the Indicator IV. Changing the Gain can change the performance of the tool when there are troubles getting good measurements. Care should be taken with this. Altering the gain is more likely to decrease the quality of most measurements rather than improve it. The gain setting can also be used to correct for conditions that may cause the tool to measure through a bearing or similar material. Available options include (from lowest to highest): VLOW, LOW, MED, HI, VHI.

Note: MED is the default and the best choice for most measurements.

Beeper

This setting turns on or off the beeper when the tool is properly coupled and making an ultrasonic measurement. It also turns the beeper on or off when any button is pressed.

Lights

This selection turns the front LED on or off when the tool is properly coupled and making an ultrasonic measurement. These LEDs will alternate between red and green when the probe is strongly coupled and this setting is on.

Language

This function changes the language of the text displayed by the tool. Languages available include English, German, French, Portuguese, and Spanish.

Date Format

This function selects the date format used by the Indicator IV. The options are Month/Day/Year(MM/DD/YYYY) and Day/Month/Year(DD/MM/YYYY.

Units

This selection sets the default units the Indicator IV measures in. The options are MM (millimeters) and IN (inches).

Odometer Units

This selection sets the default units the Indicator used for the Odometer Locations in the Inspection Mode. The options are: KM (kilometers), Hours and Miles.

Decimal Separator

This changes the method the Indicator IV displays the separator between whole and partial numbers. The options are decimal point (.) or comma (,).

Shut Off Time

This function controls the time before the Indicator IV automatically shuts off to extend battery life. The options are 2.5 minutes, 5.0 minutes, 10 minutes, and OFF. When OFF is selected, the tool will remain on until the user turns it off, or the batteries discharge.

Edit Custom Inspection

This function sets which locations will be displayed in the Inspection Mode when Custom is selected by the user in the Inspection Mode setting of the Preferences Menu. Pressing Enter on this selection changes the screen to the Custom Inspection Mode screen. In this screen, press the up and down arrows to select a location field. The order of the locations displayed can be changed by pressing the left and right arrows when the field you wish to move is selected. Pressing the CLR key causes the selected field to be either hid or shown in the Inspection Mode. When done editing the Custom Inspection display, press the SAVE key to return to the Preferences Menu. The ESC key can be pressed at any time to return to the Preferences Menu without saving.

Reset Custom Inspection

This function returns the Custom Inspection screen to default without manually resetting each location. Pressing Enter on this selection changes the display to show a confirmation screen. Press the Enter key again to reset the Custom Inspection location list to default. Press the ESC key to return to the Preferences Menu without resetting the Custom Inspection.

About UWI 4

This function displays the version information about the Indicator IV. Pressing the ENTER key, the Left Arrow key, or the right arrow key, displays the ABOUT screen. This screen shows the Indicator part number, software version, serial number, and FPGA version. Press the ESC key to return to the Preferences Menu.

Battery Level Monitor

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 display in most screen of the tool. It will not display in the Preferences Menu, or Machine Mode screens. A visual representation of a battery is shown in the upper left-hand corner of the tool. This icon will contain a bar that represents the remaining battery charge. As the battery drains down the bar will shorten.

Low Battery Indication

The Battery Level Indicator will display an almost completely empty battery when the battery charge drops to a low level. The Indicator IV shuts down when the battery voltage reaches approximately 2.8V.

Return to Last Menu Screen

The Indicator IV will remember the last machine and locations displayed on screen when the Indicator IV was last turned OFF. When the Indicator IV is turned ON again, the last selected Machine and Location will still be selected.

Checking the Operation of the Indicator IV

The following procedure may be used to check the operation of the 415-4051 Ultrasonic Wear Indicator IV and the 415-4052, 168-7722, or 4C-5485 Probe. The only components required for the test are the 415-4051 Ultrasonic Wear Indicator IV , the 415-4052, 168-7722, or 4C-5485 Probe and the 9U-7981 Couplant . Perform all the procedures, as shown in the Operating Instructions for the 415-4051 Ultrasonic Wear Indicator IV in this manual. Instead of measuring undercarriage components, the metal calibration disk should be measured and the MEASURED VALUE saved, and the MEMORY VALUE displayed to check for accurate readings. The metal calibration disk should read wither 10.5 mm (0.41 inches or 0.42 inches).

Alternated 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 that they operate correctly. If the Indicator IV does not operate properly during this test, refer to the Troubleshooting section in this manual.

2. Next, test the Indicator IV 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 the measurements can be taken on very thick undercarriage components such as through track shoe grouser bars.

4. If the Indicator IV 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 IV.

Updating the Ultrasonic Wear Indicator IV Firmware

The 415-4051 Ultrasonic Wear Indicator IV has on-board software (often called firmware) that can be updated to enhance the tool for future features. This document covers how to update this firmware in the 415-4051 when these updates are available.

Please check the Dealer Service Tools website at: https://dealer.cat.com/dealer-service-tools for any software and firmware updates for this tool.

To update the 415-4051 Ultrasonic Wear Indicator IV, you will need the following:

1. The UWI4 firmware update software installed on a PC

2. A USB to serial adapter such as the one included with the 415-4055 group

3. A serial to 2 pin Lemo style communication cable such as the one provided in the 415-4055 group

4. A current firmware file saved on the PC with the update software

Installing the UWI4 Firmware Update Software

To install the UWI4 firmware update software, save the UWI4_inst.exe file to the hard drive of a USB equipped Windows XP, Vista, or Windows 7 PC. Double click on this file to run it. On some operating systems, a warning window may appear asking if this application should be allowed to run. Click YES to continue. After a few seconds, an installation wizard should launch.

Illustration 38	g03394326

Click on the NEXT button to continue. The Cancel button can be clicked to exit this installation.

The next screen will ask where you would like to install the application. Select the Choose button to manually select the directory, or the Next button to select the currently selected installation directory. The Previous button will take you back a screen, and the Cancel button will exit the installation.

Illustration 39	g03395473

The next screen asks where you would like icons and shortcuts to be installed. Make your desired choices and press the NEXT button to continue.

Illustration 40	g03395475

The Pre-Installation Summary shows summaries of the selections you have made and the disk space required and available. Press the NEXT button to continue.

Illustration 41	g03395479

The installer will now install the UWI4 firmware update software. A status bar indicates the progress of the installation.

Illustration 42	g03395486

Once installation is complete, an Install Complete screen will display. Press the DONE button to exit the installer.

Illustration 43	g03395488

Connecting the Flash Communication Cables to the PC

The Ultrasonic Wear Indicator IV uses serial communications to update its internal firmware. A USB to serial adapter and communications cable to do this is provided in the 415-4055 group.

Illustration 44	g03395509

Remove the rubber plug from the communications port on the bottom of the Ultrasonic Wear Indicator IV.

Illustration 45	g03395514

Plug the round barrel connector of the serial communication cable into the exposed communication port. Notice the red dot on both connectors to aid in alignment.

Connect the 9 pin D-shell connector to the USB to serial adapter. Next, connect the USB connector of the adapter to the PC's USB port.

Using the UWI4 Firmware Update Software

Launch the UWI4 firmware update software from the shortcut selected during the installation process, or from the Start/Programs menu.

Illustration 46	g03395519

A splash screen will appear after a few seconds.

Illustration 47	g03395523

After the splash screen, the main application window will appear.

The Settings menu allows the user to select the appropriate Com port used to communicate with the Ultrasonic Wear Indicator. Use this menu to select the appropriate Com port if known, or the Auto selection.

After selecting the Com port, press the Upgrade UWI IV button to begin the firmware update process.

Illustration 48	g03395540

An Upgrade Settings window will appear.

Use the drop box to select the communication speed for the update. This selection should be set to 115200 in almost all cases. Using other selections is not advised. The Software Upgrade radio button should also be selected. The hardware upgrade requires partial disassembly of the tool and is not advised.

After checking these selections, press the OK button to continue.

Illustration 49	g03395542

An Upload to Gauge selection window will appear. This window allows you to navigate to find the firmware file saved on the PC.

Illustration 50	g03395543

Select the firmware file to be installed, then press the Upload button to continue.

Illustration 51	g03395545

A Data Transfer Progress window will appear asking you to activate the gauge.

Illustration 52	g03395548

To activate the Ultrasonic Wear Indicator in a mode to accept the firmware file, you must hold the Menu button while turning the tool on with the On/Off button. As soon as you do this, the Indicator will display a warning message:FLASH MODE, UPGRADING, FIRMWARE, CAUTION!, DO NOT POWER, OFF UNTIL and COMPLETED.

If the tool is powered off or unplugged during the firmware update, it could render the tool unable to operate and be unflashable with new firmware. This is correctable at a service center, but not without special equipment. So, care should be taken to avoid disruptions of the update from this point on.

Illustration 53	g03395569

A Data Transfer Progress window will appear on the PC showing the transfer progress. Pressing Cancel will stop the transfer, but is not advised. Doing so at the wrong time can cause the loss of the firmware and render the tool unable to update outside of a service center.

Illustration 54	g03395570

When the transfer is complete, the Data Transfer Progress window will disappear and return you to the main application screen. The tool will automatically power off.

You can close the update application at this point and disconnect the tool. Powering on the tool should show you an updated version on the splash screen of the tool, or the About Ultrasonic Wear Indicator IV menu option.

Troubleshooting

If the Indicator IV does not operate properly, first check the Battery Level Monitor to see if the batteries have sufficient power remaining. If not, then recharge or replace them with new alkaline batteries. As the rechargeable batteries age, they will provide less operating time for the Indicator IV. When the operating time between charging is unacceptable, the batteries should be replaced with new rechargeable batteries.

Note: Follow the battery manufacturer instructions and recommendations for proper battery charging.

If the Battery Level Monitor shows that the batteries have sufficient power remaining and the Indicator IV still will not turn ON, it must be sent in for repair. Refer to the Service section in this manual.

If the display comes on but the Indicator IV will not take measurements, the problem may be in the probe. If you have another probe that is known to be good, try it and see if it works. If not, use the following procedures:

1. Take the Indicator IV to a quiet place.

2. Put the probe close to your ear.

3. Turn the Indicator IV ON.

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

5. Remove the probe cable connector from the Indicator IV and turn it around in the PROBE connector.

Note: Again, with the Indicator IV 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. In some cases you may be able to make a failed probe work for a short period by reversing the orientation of the connector when inserting it in the PROBE connector. The probe is calibrated to work plugged in either way.

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, first clean the probe face. If that does not correct the problem then try adjusting the gain of the Indicator IV. If this also fails to correct the problem, replace the probe.

If you are unable to enter data into an inspection field: Verify that the Inspection Mode selected in the Preferences menu includes the field you are trying to edit. If it does and the problem continues, next verify that the keys on the keypad are working. If the keys are failed or you still cannot enter data into the location, then your tool may need to be repaired.

If the Indicator IV does not seem to be measuring correctly; First, check the calibration of the tool on the calibration disk. The calibration disk should measure either 0.41 or 0.42 In (10.5 mm). If it does not, recalibrate the probe and try again. In some cases it is necessary to perform a manual calibration, followed by an automatic calibration to fully set the calibration of a probe. This should be uncommon. If recalibrating the probe does not correct the issue or if you frequently need to perform both calibrations on a probe then the probe is likely to be damaged. Check the tool with another probe. If another probe does not correct the problem then verify the material being measured. Different materials have different ultrasonic velocities that will affect the accuracy of the reading. The default velocity for the Indicator IV is for mild carbon steel. If none of this corrects the issue, then the tool may need to be repaired.

Location Display Map

Fields Displayed on Each Inspection Mode

Table 10

Full Inspection	Partial Inspection	Ultrasonic Inspection	Partial Ultrasonic Inspection
Model	Model	Model	Model
Serial Number	Serial Number	Serial Number	Serial Number
Date	Date
Hour Meter Reading	Hour Meter Reading
Total Odometer	Total Odometer
Forward Odometer	Forward Odometer
Reverse Odometer	Reverse Odometer
Odometer Units	Odometer Units
Job Site	Job Site
Impact Conditions	Impact Conditions
Abrasive Conditions	Abrasive Conditions
Moisture Conditions	Moisture Conditions
Packing Conditions	Packing Conditions
Bushing Allowable Wear	Bushing Allowable Wear
Link Allowable Wear	Link Allowable Wear
Left Track Sag	Left Track Sag
Left Frame Extension
Left Dry Joints
Link Part Number
Left Link	Left Link	Left Link	Left Link
Left Bushing Internal
Bushing Tool	Bushing Tool
Left Bushing External	Left Bushing External	Left Bushing External	Left Bushing External
Shoe Tool	Shoe Tool
Left Shoe	Left Shoe	Left Shoe	Left Shoe
Left Front Idler Depth
Left Front Idler Sonic		Left Front Idler Sonic
Left Rear Idler Depth
Left Rear Idler Sonic		Left Rear Idler Sonic
Carrier Roller Tool
Left Carrier Roller 1*		Left Carrier Roller 1*
Left Carrier Roller 2*		Left Carrier Roller 2*
Left Carrier Roller 3*		Left Carrier Roller 3*
Track Roller Tool	Track Roller Tool
Left Track Roller 1 **	Left Track Roller 1 ** (front)	Left Track Roller 1 **	Left Track Roller 1**(front)
Left Track Roller 2 **		Left Track Roller 2 **
Left Track Roller 3 **		Left Track Roller 3 **
Left Track Roller 4 **		Left Track Roller 4 **
Left Track Roller 5 **		Left Track Roller 5 **
Left Track Roller 6 **		Left Track Roller 6 **
Left Track Roller 7 **		Left Track Roller 7 **
Left Track Roller 8 **		Left Track Roller 8 **
Left Track Roller 9 **		Left Track Roller 9 **
	Left Track Roller 10 **		Left Track Roller 10 **
Left Track Roller 10 **	(rear)	Left Track Roller 10 **	(rear)
Left Sprocket Measurement
Left Sprocket Condition
Right Track Sag	Right Track Sag		Right Track Sag
Right Frame Extension
Right Dry Joints
Right Link	Right Link	Right Link	Right Link
Right Bushing Internal
Right Bushing External	Right Bushing External	Right Bushing External	Right Bushing External
Right Shoe	Right Shoe	Right Shoe	Right Shoe
Right Front Idler Depth
Right Front Idler Sonic		Right Front Idler Sonic
Right Rear Idler Depth
Right Rear Idler Sonic		Right Rear Idler Sonic
Right Carrier Roller 1 *		Right Carrier Roller 1 *
Right Carrier Roller 2 *		Right Carrier Roller 2 *
Right Carrier Roller 3 *		Right Carrier Roller 3 *
Right Track Roller 1 **	Left Track Roller 1 ** (front)	Right Track Roller 1 **	Left Track Roller 1 ** (front)
Right Track Roller 2 **		Right Track Roller 2 **
Right Track Roller 3 **		Right Track Roller 3 **
Right Track Roller 4 **		Right Track Roller 4 **
Right Track Roller 5 **		Right Track Roller 5 **
Right Track Roller 6 **		Right Track Roller 6 **
Right Track Roller 7 **		Right Track Roller 7 **
Right Track Roller 8 **		Right Track Roller 8 **
Right Track Roller 9 **		Right Track Roller 9 **
	Left Track Roller 10 **		Left Track Roller 10 **
Right Track Roller 10 **	(rear)	Right Track Roller 10 **	(rear)
Right Sprocket Measurement
Right Sprocket Condition

* Carrier roller quantity will vary based on the data sent from CTS

** Track roller quantity will vary based on data sent from CTS

*** Standard measurement field size = 0.00 in/000.0 mm

Highlighted fields can be measured by the ultrasonic tool.

Maintenance

Material Safety Data Sheets (MSDS)

Refer to the current Material Safety Data Sheets (MSDS) for the 9U-7981 Couplant.

Service

If the Ultrasonic Wear Indicator IV does not operate correctly, recharge or replace the internal batteries with new ones and check the operation. If it still does not operate, refer to the Troubleshooting section in the manual. If the Indicator IV is found to be faulty, contact Dealer Service Tools for information on how to obtain the needed repair service.

Warranty

Dealer Service Tools provides the instrument user with a warranty of one year from the purchase date. If the reason for failure is determined to be from abuse, the warranty is declared void. Any out-of-warranty repairs will be charged to the owner.

Additional Contact Information

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

USA: 800-542-8665, Option 1

International: 1-309-578-7372

E-mail: dealerservicetool_hotline@cat.com

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

Notes

Table 11