1U9800 Ultrasonic Wear Indicator Group{0767} Caterpillar

Introduction

The 1U9800 Ultrasonic Wear Indicator Group provides a new, fast and accurate method of measuring track type machine undercarriage wear.

By placing a probe on the part to be measured, the Ultrasonic Wear Indicator 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.

At a later date a Custom Track Service (CTS) personal computer program will be available to provide an undercarriage wear report automatically from the stored measurements.

This new CTS tool provides a professional alternative for the mechanical CTS tool kit.

The Ultrasonic Wear Indicator measures 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 converts the time into a thickness value and displays it.

When taking measurements, the 1U9802 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 wear indicator.

Benefits of the Ultrasonic Wear Indicator

For many years, CTS inspectors have used the mechanical CTS kit to measure undercarriage wear. While this method worked, the new Ultrasonic Wear Indicator has many benefits over the previous measurement method.

These benefits are listed below.

* Higher accuracy measurements - Digital display of thickness accurate to 0.1 mm or (0.01")...

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

* Easy to use - Thickness reading will always appear on display when probe is used regardless of mode of operation.

* Calibrated for undercarriage steel, but velocity can be adjusted to accurately measure other materials such as aluminum, plastic and glass.

* Reads thickness of parts where opposite side is not accessible such as bulldozer blade, bucket base edge, and scraper bowl thickness.

* No writing - Stores readings in memory then transfers to computer for printing.

* Less time cleaning parts - Only a small surface on the wear area must to be clean. 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 64 machines.

* All CTS inspectors measure with same accuracy.

NOTE: A computer program will be available later for automatic percent wear and projected life calculations.

* Prompts CTS inspector on next reading location.

1U9800 Ultrasonic Wear Indicator Group

1. 1U9801 Ultrasonic Wear Indicator. 2. 4C5485 Ultrasonic Probe. 3. 1U9802 Couplant. 4. 6V7145 Carrying Case. 5. 4C4772 Foam Insert. 6. 4C3024 Battery Charger (110/220 Volts AC, 50/60 Hz). 7. 8T9200 Paper Towels.

SEHS9089 Using the 1U9800 Ultrasonic Wear Indicator Group.NEEG2428 1U8900 Group label (located in lid of 1U9800 Group Carrying case).

Five 1 9/16" protective plastic caps for RS232 connector.

Storage of Conventional CTS Tools in 6V7145 Carrying Case.

CTS conventional tools stored with the 1U9800 Ultrasonic Wear Indicator Group.

Because some undercarriage components cannot be measured with the 1U9801 Ultrasonic Wear Indicator, 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.

1 - PEKP9400 Custom Track Service Handbook: Fits under 1U9801 Ultrasonic Wear Indicator.

2 - 5P3277 Tape Measure: 3 m (10 ft) for pitch, sag, and sprocket measurement.

3 - 8H8580 Scraper: For cleaning undercarriage components.

4 - 5P8616 Sprocket Gauge: For D4, D5, and D6 track type tractors.

5 - 5P8617 Sprocket Gauge: For D7, D8, and D9 track type tractors.

6 - 6V9410 Depth Gauge: For measuring idlers.

5P3920 Steel Rule: 300 mm (12"), store on top of 8T9200 Paper Towels.

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

Optional Items For Use With the 1U9801 Ultrasonic Wear Indicator

1 - 4C5489 Cable Assembly RS232 (PC XT Version): For connecting the 1U9801 Ultrasonic Wear Indicator to an IBM© XT, or compatible, personal computer. Has 25 pin type D connector (DB25F).

2 - 4C5488 Cable Assembly RS232 (PC AT Version): For connecting the 1U9801 Ultrasonic Wear Indicator to an IBM© AT, or compatible, personal computer. Has 9 pin type D connector (D89F).

3 - 1U7445 NiCad (Nickel Cadmium): Rechargeable battery (size AA).

4 - 1U9533 Alkaline: Non-rechargeable battery (size AA).

NOTE: Five batteries are required to power the 1U9801 Ultrasonic Wear Indicator.

* The 1U7445 NiCad, rechargeable battery is packaged in a quantity of 1.

* The 1U9533 Alkaline non-rechargeable battery is packaged in a quantity of 96.

4C5897 Cable Assembly RS232 (Modem Cable): For connecting 1U9801 Ultrasonic Wear Indicator to a modem which transfers data over telephone lines to a personal computer.

Software program for transferring stored measurements from the 1U9801 Ultrasonic Wear Indicator to an IBM© PC, or compatible, computer for storage or printing. Also required when modem is used.

Instructions are included to operate program and modem:

* NETG5002 Transfer program on 5.25 inch disk.

* NETG5003 Transfer program on 3.5 inch disk.

Additional Service Replacement Parts

4C4041 Switch (Membrane): Service replacement for the front panel keypads (membranes). 8T0844 Cover: The service replacement for the rear cover. 4C5490 Couplant Holder: The service replacement for the holder that stores the U9802 Couplant container.

1U9800 Ultrasonic Wear Indicator Group Specifications

Input Power Required: Power is supplied by five 1U7445 NiCad (Nickel Cadmium), rechargeable, battery (size AA).

The indicator will also work with non-rechargeable Alkaline batteries.

Show/hide table

NOTICE
DO NOT attempt to recharge alkaline batteries using the 4C3024 Battery Charger. Attempting to charge an alkaline battery can result in damage to the 1U9801 Ultrasonic Wear Indicator. Place a piece of tape over the charge connector, to prevent charging, when using alkaline batteries.

Low Battery Indication: The Liquid Crystal Display (LCD) will blink when battery voltage gets down to 6.1 Volts and approximately one hour of life remains.

The LCD will go blank and not turn on when battery voltage is less than 5.8 Volts.

* NiCad Rechargeable 12 Hours

* Alkaline Non-rechargeable 30 Hours

Power Line Operation: When using the 4C3024 Battery Charger the 1U9801 Ultrasonic Wear Indicator can be powered from 110 or 220 Volts AC, 50/60 Hz. Measurement Range (Steel): 1.27 mm (0.050") to 254 mm (10.00"). Measuring Resolution: ± 0.1 mm or (0.01"). Measurement Accuracy: ± 0.1 mm or (0.01"). Operating Temperature: -18°C to 60°C (0°F to 140°F). Storage Temperature: -40°C to 60°C (-40°F to 140°F).

Ramdon Access Memory (RAM) 32,768 BytesRead Only Memory (ROM) 16,384 Bytes

External Dimensions

6V7145 Carrying Case - 1U9800 Group Case: 432 x 390 x 114 mm (17 x 15.4 x 4.5")

1U9800 Indicator - 190 x 168 x 40 mm (7.5 x 6.6 x 1.6" Inches)

1U9800 Group - 3.061kg (6.75 lb)1U9801 Indicator - 0.907kg (2.0 lb)4C5485 Probe - 0.113kg (0.25 lb)

4C5485 Ultrasonic Probe Specifications

Probe Type: Dual Element 8MHz special application. Probe Size: Measuring Surface Diameter - 9.5 mm (0.374"). Probe Length: 46 mm (1.81"). Probe Diameter: 19 mm (0.748"). Allowable Surface Temperature: -18°C to 150°C (0°F to 300°F). Cable Length: 1066 mm (42"). RS232 Specifications: 300 or 1200 Baud rate

Connections to the 1U9801 Ultrasonic Wear Indicator

1 - 1U9802 Couplant: Stored in pump type dispenser.

A small amount of couplant must be applied to the sensing end of the 4C5485 Ultrasonic Probe, before measuring, to couple ultrasonic sound into the material being measured.

2 - 4C5490 Holder: Used to hold the 1U9802 Couplant dispenser.

3 - Steel Calibration Disk: The disk is 6.3 mm (0.25") thick and is used to check the accuracy of the indicator and recalibrate the indicator if necessary.

Refer to Calibrating the Ultrasonic Wear Indicator in this publication.

4 - RS232 Connector: Used to connect the;

* 4C5488 Cable Assembly RS232 (PC AT Version) ... or

* 4C5489 Cable Assembly RS232 (PC XT Version) ... or

* 4C5897 Cable Assembly RS232 (Modem Cable).

These cables can be used to transfer stored undercarriage data from the 1U9801 Ultrasonic Wear Indicator to a personal computer or printer.

Refer to Optional Items For Use With the 1U9801 Ultrasonic Wear Indicator, in this publication, for each cables specific function and software program requirements.

5 - Charger Connector: Used to connect the 4C3024 Battery Charger when recharging the 1U7445 Batteries (Nicad).

This connector can also be used to power the 1U9801 Ultrasonic Wear Indicator with the 4C3024 Battery Charger.

6 - Probe Connector: Used to install the 4C5485 Ultrasonic Probe.

1U9801 Ultrasonic Wear Indicator Description

Abbreviations and Descriptions on Front Panel

1U9801 Ultrasonic Wear Indicator front panel and keypad.

Abbreviations and descriptions used on front panel keypad:

1 & 16 - MACH: Machine, referred to as MACH(ine) in this instruction.

2 - 6.3MM (.25 IN): Describes the exact thickness in mm and inches of the metal calibration disk (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 For Use With the 1U9801 Ultrasonic Wear Indicator, in this instruction, for each cables specific function and software program requirements.

4 - CHARGE: Identifies the connector, located on top panel, for the 4C3024 Battery Charger.

5 - PROBE: Identifies the connector, located on the top panel, for the 4C5485 Ultrasonic Probe.

6 & 16 - LOCATION and LOC: Location, referred to as LOC(ation) in this instruction. Refers to undercarriage data locations.

17 - PROBE CAL: Probe Calibration.

Description of Displays and Keys

7 - MACH (machine) 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 arrow keys and shows the machine model when in the MACH(ine) mode of operation.

The display, in the illustration, 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.

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.

11 - 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.

12 - CLEAR: Clears all MEMORY VALUE information from storage for the MACH(ine) number shown on display.

NOTE: The CLEAR and SAVE key must pressed at the same time to clear memory.

13 - 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.

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.

If a MEMORY VALUE digit is flashing,

* Press the up arrow key to advance through numbers and alphabet until desired digit is on display. This is SET DIGIT mode of operation.

14 - Down Arrow: Use to move the display in the opposite direction as the up arrow.

NOTE: Arrow keys will change display once every time pressed or may be held down to scroll (change) the display at a faster rate.

15 - 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 publication.

16 - MACH/LOC: Changes from the MACH(ine) mode to LOC(ation) mode of operation.

The MACH mode - LOCATION display will show the letters MACH.

* Use the arrow keys to move to any of the 64 machine storage locations.

The LOC mode - LOCATION display does not show the letters MACH but instead describes the inspection information or undercarriage measurement location:

* Use the 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 - PROBE CAL: Calibrates the ultrasonic probe so the indicator will read accurate.

To use, apply couplant to the sensing end of the probe and press probe to the 6.3 mm (0.25") disk on top of indicator.

If the MEASURED VALUE display is not 6.3MM or .25IN press PROBE CAL while holding the probe on the disk and it should read correctly.

Refer to Calibrating the Ultrasonic Wear Indicator and Checking the Ultrasonic Velocity in this publication.

18 - SET DIGIT: Used for manual entry of values.

When pressed, a digit on the display will flash:

* Then use arrow keys to select the desired digit.

* Press SET DIGIT again to move to the next digit.

* Press SAVE to leave the display as selected.

If a word appears for MEMORY VALUE:

* Press SET DIGIT to select other words available.

19 - ON/OFF: Turns Indicator ON or OFF.

Indicator will automatically turn off after 5 minutes if not in use.

This function can be disabled with an internal switch.

Refer to Setting the Internal Switches in this publication

NOTE: The memory information is saved when the indicator is OFF as long as the batteries are good.

Refer to 1U9800 Ultrasonic Wear Indicator Group Specifications in this instruction.

Charging the Internal 1U7445 NiCad (rechargeable) Batteries

The 1U9800 Ultrasonic Wear Indicator Group is provided with a 4C3024 Battery Charger (1) and 1U7445 NiCad (Nickel Cadmium), rechargeable, batteries, (size AA).

The batteries must be charged before using the 1U9800 Ultrasonic Wear Indicator Group.

Rear view of 4C3024 Battery Charger.

1. Move switch (1) on the rear of 4C3024 Battery Charger (2) to the correct AC line voltage, either 120 Volts or 230 Volts for the power you are using.

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

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

NOTE: For operation outside the U.S.A., an AC power plug adapter may be required.

3. Turn the indicator 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.

When first turned ON, the display may flash, indicating low voltage. The flashing should stop after a few minutes as the batteries come up in voltage.

Turn the Indicator OFF and leave the charger on for 10 to 12 hours.

NOTE: The Indicator 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 fully discharged.

Replacing the Internal 1U7445 NiCad (rechargeable) Batteries

The 1U9801 Ultrasonic Wear Indicator is provided with five 1U7445 NiCad (Nickel Cadmium), rechargeable, batteries, (size AA).

These can be replaced with new 1U7445 Batteries when they no longer give sufficient operating time, or they can be replaced with 1U9533 Alkaline (non-rechargeable) batteries.

NOTE: If the internal batteries are removed for more than five minutes all memory values in the indicator will be permanently lost.

Back view of 1U9801 Ultrasonic Wear Indicator.

1. Remove six screws (1) from cover (2).

2. Remove cover (2).

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

NOTE: The + terminal of the battery must be placed on the red terminal of the battery holder.

4. Install rear cover (2) and replace six screws (1).

Care and Cleaning of the 1U9801 Ultrasonic Wear Indicator

Care of the 1U9801 Ultrasonic Wear Indicator

The 1U9801 Ultrasonic Wear Indicator 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 water resistant but not waterproof and the indicator can be damaged if water is allowed to enter the case.

If moisture does enter the case, the indicator should be allowed to dry out. Remove the rear cover and allow it to dry completely in a warm, dry area.

Keep the indicator stored in the carrying case when not in use.

Removing the 1U9802 Couplant Residue

When taking measurements, all excess 1U9802 Couplant residue should be removed from the probe, indicator, 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. However, care must be taken so no water enters the indicator case.

Cleaning the Case and Front Panel Keypad

Care of Connectors

The RS232 and PROBE connectors, on the end of the indicator, must be kept cleaned. 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 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.

Operating Instructions for the 1U9801 Ultrasonic Wear Indicator

Plug the connector on the end of the 4C5485 Ultrasonic probe cable into the PROBE connector on the top of the indicator.

To turn the Indicator ON:

* Press and release the ON/OFF key.

Copyright display.

The display will show the copyright display for a short time, then automatically change to a MACH (machine) display similar to those shown below.

MACH display (Memory Clear).

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 the internal memory for the machine number shown is clear (contains no stored information) it will appear as the MACH display shown above.

MACH display (Last MACH used).

The example above shows the MACH display with the model and serial (product identification) number of the last MACH used shown.

The MACH(ine) number may be selected with the arrow keys.

If the MACH(ine) number will not change:

* Press the MACH/LOC key to get to the MACH display as shown above.

* Then use the arrow keys again.

Calibrating the Ultrasonic Wear Indicator

Before taking measurements the accuracy of the Ultrasonic Indicator must be checked and the indicator recalibrated if needed.

This procedure should be performed at the start of each day and anytime the accuracy is in question to ensure the readings taken will be accurate.

Once the Indicator is calibrated with this procedure, it will ONLY be accurate for measuring undercarriage steel or similar type steel.

If other materials are to be measured the velocity must be changed and a different PROBE CAL value used.

Refer to "Additional Details of Switch Functions [Switch (2): Ultrasonic Velocity Adjustment]" in the topic entitled Setting the Internal Switches in this publication.

1U9801 Ultrasonic Wear Indicator with 1U9802 Couplant and couplant holder.

A metal calibration disk exactly 6.3 mm (0.25") thick is used to check the accuracy and calibrate the indicator.

1. Place a small amount of 1U9802 Couplant on the sensing end of the probe.

Press the probe to the 6.3 mm (0.25") disk (1) on the top of the Indicator.

A number will appear at the MEASURED VALUE display on the indicator. If the probe is properly coupled to the disk, the MM or IN indicator will also be displayed.

Also a beeping sound will be present (if not turned off internally) to indicate good coupling.

Probe on calibration disk NOT in calibration.

The display value should be 6.3MM or 0.25IN. If it is not correct, follow the instructions in Step 2.

Probe removed from calibration disk.

If the display is as shown above the calibration is correct. Proceed to the topic Undercarriage Measurement Procedure.

2. To calibrate the indicator, press the PROBE CAL key.

PROBE CAL key pressed.

The display should now show (PROBE).

Place a small amount of 1U9802 Couplant on the sensing end of the probe.

Press the probe to 6.3 mm (0.25") disk (4) on the top of the indicator.

Calibration complete.

The MEASURED VALUE shown on the display should now be correct. If not, repeat this procedure until it is correct.

Once the correct value appears the indicator is ready to use.

An alternate method is to press the PROBE CAL key while holding the probe on the disk.

If the indicator still will not calibrate correctly check for the proper velocity setting for undercarriage.

Refer to "Additional Details of Switch Functions" [Switch (2): Ultrasonic Velocity Adjustment] in the topic Setting the Internal Switches.

Undercarriage Measurement Procedure

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

1. The indicator MUST be calibrated before any measurements are taken.

Refer to Calibrating the Ultrasonic Wear Indicator in this publication.

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

Clearing the Memory

If a (CLEAR) machine cannot be located, any machine can be cleared by pressing both the SAVE and the CLEAR keys at the same time.

Display while machine is being cleared.

The message shown above will appear on the display for a short period of time.

MACH display after clearing machine memory.

It will then be replaced with the (CLEAR) message indicating 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.

Using LOC(ation) Mode of Operation

To store ultrasonic measurements and input information about the machine being measured, the Indicator must be in the LOC(ation) mode of operation.

To change to the LOC(ation) mode from the MACH(ine) mode, press the MACH/LOC key.

This key always changes the display to the other mode of operation.

If the word MACH is not on the display the indicator is in the LOC(ation) mode.

Once in the LOC(ation) mode, the 69 different undercarriage storage locations listed below are available for use.

These storage locations can be accessed with the arrow keys.

Refer to the Undercarriage Measurement Display Map, in this publication, for additional information on how to change between the various displays.

List of Undercarriage Storage LOC(ation) Displays

MODEL display with empty MODEL number.

MODEL display containing Model number.

The first storage location is MODEL. This display is shown above in the way it appears with and without a model number in memory.

The machine model number can be entered where the dotted line is or a number already shown can be changed.

This display will always be the first display shown when switching from the MACH(ine) to LOC(ation) mode of operation.

Using the Set Digit Key to Enter Information

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.

To enter the MODEL, press the SET DIGIT key and the first number digit location will become a blinking box.

Whenever a blinking box is on the display, the arrow keys can be used to scroll through the numbers and alphabet.

When the desired number or letter appears in the box, press the SET DIGIT key again to advance the box to the next dash. 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, advance the display to the next LOC(ation) display which is SERIAL NUMBER by pressing the up arrow key.

To enter the serial (product identification) number into the SERIAL NUMBER display follow the same procedure as used in a previous topic entitled Using LOC(ation) Mode of Operation.

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.

The same SET DIGIT procedure will be used for entering:

* DATE

* HOURS

* HRS. PER WEEK

* JOB SITE .. and

Values and notes not measured by ultrasonic method.

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.

Example of IMPACT with alternate word MODERATE.

Example of IMPACT with alternate word HIGH.

Example of IMPACT with alternate word LOW.

On these displays alternate words are available. To view the other words available, press the SET DIGIT key.

The other words will appear as shown above.

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.

Measuring Track Sag

The first display for a measurement is L TRACK SAG (left track sag).

This measurement cannot be taken with the ultrasonic indicator.

It must be taken according to the instructions in the CTS handbook with a tape measure and manually entered into the Indicator memory.

To enter this measurement at the L TRACK SAG display press the SET DIGIT key.

The first digit of the MEMORY VALUE will flash, allowing the arrow keys to be used to enter the measurement number.

Refer to the topic entitled Using the SET DIGIT Key to Enter Information.

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

Taking Ultrasonic Measurements

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

NOTE: Refer to the topic entitled Undercarriage Measurement Techniques, in this publication, for details on how to measure each undercarriage component.

To take a measurement, place a small amount of 1U9802 Couplant on the sensing end of the probe and press it firmly and squarely against the wear surface.

The measurement will appear on the display above MEASURED VALUE.

An indication of proper coupling of the probe is shown by IN or MM appearing after the MEASURED VALUE.

Also a beeping noise will be heard if it is not turned off internally.

When you are satisfied a good value is on the display, remove the probe and that value will remain in the MEASURED VALUE display.

Saving Measured Values in Memory

The measured value shown on the display can be saved in the memory of the 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.

If you want to check 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.

Tool Displays

Some displays refer to the type of tool used for measurement of the component described.

If a tool other than 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.

Example of BUSHING TOOL with type of tool to be used: ULTRASONIC

Example of BUSHING TOOL with type of tool to be used: CALIPER

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

Pressing the SET DIGIT 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.

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.

1. The sequence of the undercarriage storage locations were selected to easily transfer into the Custom Track Service personal computer program which will not be available until mid 1990.

Until you have this program it may save time to enter and save only the serial number and measurements in the indicator. 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, in this publication.

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 1U9802 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 1U9802 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 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 the probe off quickly to prevent the measurement from increasing slightly as the probe is removed.

Undercarriage Measurement Techniques

Track Links

1. Measure distance from tread surface to bushing bore.

2. Place probe over the centerline of the bushing.

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

Track Shoes

Probe located on the bottom of the plate.

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

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.

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

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.

Track Bushing

1. Measure the wall thickness.

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

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

1. Measure the center flange thickness only on fabricated idlers.

Determine center flange wear from the idler wear charts in the CTS Handbook.

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

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

Carrier Roller

Three piece rims

Measure the thickness of the press-on rim.

One piece rims

Measure the distance from the outside of the tread surface to the bore.

NOTE: Due to the use of tapered roller bearings, more than one thickness can be found along each tread surface.

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

NOTE: The Ultrasonic Wear Indicator will not measure cast iron rollers.

Some D3, D4, D5, D6 tractors, and 225 excavator carrier rollers are cast iron.

Track Roller

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

2. Do not measure to the retainer bolt holes.

NOTE: On H, N, & 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 track-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.

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 undercarriage with the Ultrasonic Wear Indicator.

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 can be used to measure steel part thickness without changing any settings.

This is simple to do because the 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

* Bucket base edge

* Scraper bowl

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 must be changed.

Refer to "Additional Details of Switch Functions - [Switch (2): Ultrasonic Velocity Adjustment" in the topic entitled Setting the Internal Switches in this publication, for complete information on measuring materials other than steel.

1. Install probe, and calibrate the indicator.

Refer to the topic entitled Calibrating the Ultrasonic Wear Indicator, in this publication.

When taking measurements, the 1U9802 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 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 internally).

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.

If the reading is not correct, the velocity may be adjusted to make the indicator read accurate.

Refer to "Additional Details of Switch Functions - [Switch (2): Ultrasonic Velocity Adjustment]" in the topic entitled Setting the Internal Switches in this publication.

Transferring the Indicator Memory Values to a Computer

The information contained (saved) in the indicator memory may be transferred to an IBM© or compatible personal computer for storage or printing.

It can also be used with other programs such as the Custom Track Service (CTS) personal computer program.

Also a modem can be used with the indicator to send the memory information over phone lines to a personal computer.

The equipment and items required are:

* RS232 Cable

* Transfer Program Disk

* Modem Specifications

Refer to the topic entitled Optional Items For Use With the 1U9801 Ultrasonic Wear Indicator, in this publication, for each cables specific function and software program requirements.

* Printer, must be connected the personal computer used.

Setting the Internal Switches

Back side of 1U9801 Ultrasonic Wear Indicator with cover removed for access to the internal switches.

Four small rocker type switches are located inside the Indicator above the batteries.

Each of these switches has a number on it and controls the following functions:

Switch (1)

ON Automatic Turn Off

OFF Manual Turn Off

Switch (2)

ON Allows keypad adjustment of ultrasonic velocity.

OFF Velocity adjust disabled.

Switch (3)

ON 300 BAUD rate RS232

OFF 1200 BAUD rate RS232

Switch (4)

ON Probe coupled beeper On.

OFF Probe coupled beeper Off.

The switch settings, ON or OFF, can be viewed on the display.

Viewing the switch settings

Example 1. Screen display with switches 1, 2, and 3 ON.

Example 2. Screen display with switches 1, 2, and 3 OFF.

* Turn the indicator OFF.

* Press and hold down the SAVE key and press ON/OFF key.

When the indicator comes ON the switch setting screen is displayed as shown in Example 1 above.

Key to Switch Setting Screen Display

Switch (1)

ON AUTO TURNOFF

OFF MANUAL TURNOFF

Switch (2)

ON VEL:ON

OFF VEL:OFF.

Switch (3)

ON SER:300

OFF SER:1200

Switch (4)

Not shown on screen, use probe to determine if beeper is ON.

Changing a Switch Setting

NOTE: The rear cover on the indicator must be removed for access to the switches.

Refer to the topic entitled Replacing the Internal 1U7445 NiCad (rechargeable) Batteries, in this publication, for the procedure to remove the panel.

Turn the indicator OFF and remove the rear panel.

Use a pointed object such as a pencil or small screwdriver to change the switch setting by pressing on the side of the switch that sticks up.

When the numbered side of a switch is down the switch is ON.

When the opposite side of a switch is down the switch is OFF.

Additional Details of the Switch Functions

Switch (1) Automatic Turn Off feature.

This function allows longer battery life by automatically turning the Indicator OFF if it has not been used for five minutes.

Normal operation of the keypad ON/OFF switch is not effected.

Switch (2) Ultrasonic Velocity Adjustment.

This switch allows the ultrasonic velocity to be viewed on the display and changed using the front panel keypad.

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

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

Refer to the following chart for a list of various materials, ultrasonic velocities, and probe calibration values.

Checking the Ultrasonic Velocity

1. Remove the rear cover and press the ON side of Switch 2.

2. With the indicator ON:

* Press the MACH/LOC key ... then

* Press the MM/INCH key.

Example of screen display with VEL in MM/USEC.

Example of screen display with VEL in IN/USEC.

The velocity setting of the indicator 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.

3. If the indicator is being used to measure Undercarriage Steel, be sure it reads 5.87 MM/USEC or .231 IN/USEC as shown above.

If the number is not correct, or you plan to measure other materials, the velocity number can be changed as directed in the following topic.

Changing the Ultrasonic Velocity

1. Locate the velocity number for the material to be measured in the Velocity chart above.

The numbers given in this chart are approximate and slightly different numbers may have to be used to give accurate readings because of differences in material composition.

2. With the display showing the velocity as shown in Step 2 in the topic Checking the Ultrasonic Velocity, press the SET DIGIT key.

The first digit of the velocity number will flash. Use the arrow keys to set this digit to the desired number.

3. Press the SET DIGIT again to set the other two digits.

4. When the desired velocity number is shown on the display press the SAVE key and the indicator will now be set for the new material.

5. 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 6.3MM (.25IN) 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 6.3MM or (.25IN).

6. Measure a known thickness of the new material with the Indicator to be sure the readings are accurate.

7. If the readings are not exact, change the velocity setting number right hand digit by one and recalibrate.

8. Measure the material again and continue this process until the indicator reads correctly.

Switch (3) 300 OR 1200 BAUD Rate Selection Switch.

This switch controls the speed of the RS232 communications signal.

NOTE: For additional information on setting this switch refer to the downloading and modem use instructions provided with the communications disk.

Switch (4) Probe Coupled Beeper Control.

This selector switch turns ON or OFF the beeper that sounds when the probe is properly coupled to the material being measured.

When it is turned OFF coupling will still be indicated by MM or IN being displayed beside the MEASURED VALUE when properly coupled.

Viewing the Software Version Screen

The version number of the software that is in use in the Ultrasonic Thickness Indicator can be viewed on the display in the following manner.

1. Turn the indicator OFF.

2. Press and hold down the LOC/MACH key and press ON/OFF to turn the indicator ON.

Example of screen display for SOFTWARE VERSION number.

3. When the indicator comes on the software version screen is displayed as shown above.

To leave this screen, turn the indicator OFF.

The software is the program that operates the microprocessor in the indicator. It is contained in a replaceable Program Module located in the indicator.

If a change is made to the software this module will be made available and can be installed by the user of the indicator.

NOTE: At a later date different Program Modules will be available to provide different language displays for the indicator.

Replacement of the Program Module

1. With the indicator turned OFF, remove six screws from the rear cover and remove the cover.

Back side of 1U9801 Ultrasonic Wear Indicator with cover removed for access to the Program Module.

2. Locate and remove Program Module (1) in the center of the large printed circuit board above the batteries.

3. Install the new Program Module into the empty socket.

NOTE: The Module and socket are keyed so it can only be installed in the correct (seated) position.

4. Locate small connector (2), near the upper right corner of the battery holder which has two wires coming from it.

5. Separate connector (2) by pulling gently on the plug.

This will disconnect the batteries from the indicator to prevent damage while changing the program module.

Once the connector is separated, two pins will be seen on the part of the connector still attached to the circuit board.

6. Use a screwdriver or paper clip to short these two pins together for at least five seconds.

Reconnect the two halves of the two pin connector and push them together until they snap into place.

This will reset the indicator microprocessor.

7. Install the rear cover and the six screws.

8. Turn the indicator ON and check for correct operation.

Checking the Operation of the 1U9801 Ultrasonic Wear Indicator

The following procedure may be used to check the operation of the 1U9801 Indicator and 4C5485 Probe.

The only components required for the test are the 1U9801 Indicator, 4C5485 Probe, and 1U9802 Couplant.

Perform all the procedures as shown in Operating Instructions for the 1U9801 Ultrasonic Wear Indicator, in this publication.

Instead of measuring undercarriage components, the 6.3MM (.25 IN) calibration disk should be measured and the MEASURED and saved, and the MEMORY VALUE displays checked for accurate readings.

Alternate Method for Checking the Operation of the 1U9801 Ultrasonic Wear Indicator

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.

If the indicator does not operate properly during this test, refer to the topic Troubleshooting, in this publication.

2. Next, test the indicator 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.

* If the indicator has trouble making any of these readings the gain may need to be adjusted.

Refer to the topic Troubleshooting, in this publication, for the procedures to adjust the gain.

This completes the test of the indicator.

Troubleshooting

If the indicator does not operate properly, first check the battery voltage and recharge if needed, or replace them with new fully charged batteries.

The battery voltage should be measured at the two pin connector beside the battery holder.

To operate properly, the battery voltage must be at least 5.8 Volts.

Below this voltage the indicator will not turn ON.

The display will flash if the voltage is below approximately 6.1 Volts.

As the rechargeable batteries age, they will provide less operating time for the indicator.

When the operating time between charging is unacceptable, the batteries should be replaced with new NiCad batteries.

NOTE: The longest life will be obtained by charging the batteries only after the display is flashing, indicating the batteries are fully discharged.

If the battery voltage is good and the indicator still will not turn ON, it must be sent in for repair.

Refer to the topic Service in this publication.

If the display comes on but the indicator 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:

* Take the indicator to a quiet place.

* Put the probe close to your ear.

* Turn ON the indicator.

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

Remove the probe cable connector from the indicator and turn it around in the PROBE connector so the tab is at the rear of the indicator.

The cable connector will not fit completely against the connector panel but will still make contact.

Again with the indicator 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.

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.

* If this fails to correct the problem, replace the probe.

Adjusting the Gain of the Indicator

If the gain setting is out of adjustment it will result in inaccurate or hard to get readings, or no echo.

NOTE: The gain adjustment is set at the factory using precision instruments and should not be changed unless absolutely necessary.

Back side of 1U9801 Ultrasonic Wear Indicator with cover removed for access to the gain adjustment.

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.

2. Locate gain adjustment (1) on the top printed circuit board.

It is the only screwdriver adjustment and is located directly behind the PROBE connectors.

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 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 during this procedure.

4. Turn internal selector Switch 4 (Probe Coupled Beeper Control) ON so the probe coupled beeper will operate.

5. To adjust the gain, use a small screwdriver to turn the gain adjustment while measuring a thick undercarriage such as a large track roller or shoe grouser.

Turning the adjustment CLOCKWISE (right) decreases the gain until no echo is received (no beeping is heard and no measurements will be taken).

Turning the adjustment COUNTERCLOCKWISE (left) increases the gain.

If the gain is increased too much the beeper will not turn off when the probe is removed from the component being measured.

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.

Once this setting is obtained, replace the rear cover.

Service

If the indicator 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 topic Troubleshooting in this publication.

If the indicator is found to be faulty use one of the addresses or telephone numbers that follow, to contact the Caterpillar Service Technology Group.

UPS and EMERY only:

Telephone:

1-800-541-8665 Inside Illinois

1-800-542-8665 Outside Illinois

1-800-523-8665 Canada

Outside of North America use Telex #404435

* If the tool, or any part of it, is sent Caterpillar for repair, be sure to first contact the Caterpillar Service Technology Group as indicated.

* Before sending the tool, be sure to enclose a letter that describes the problem, and give the date of purchase from Caterpillar.

Tools that are less than one year old will be repaired under warranty (except for abuse).

The cost of out of warranty will be charged to the owner.

U.S. Mail

Undercarriage Measurement Display Map

LOC(ation) Display Map

LOC(ation) Display Map (Continued)