CAT 3500b Application Guide

The Caterpillar Engine Simulator 3500B-1

3500BApplication Guide

3500B Basic Engine

The 3500B Basic Engine application is a software training module for the Caterpillar Engine Simulators Electronic Training Aid program. This module provides information about genset, marine, and machine engine control systems.

The following pages include specifications for Simulator setup and general information.

3500B ApplicationApplication Information


EUI System Specs

ECM Harness Port Connections

ECM 7X6322

ECM Harness 128-1171

ECM Harness Port Connect to Ports A & B

Personality Module 35BTAID-01

Engine Component Panel Voltage Selector

Set to local voltage(115Vac OR 220Vac)

ECM Power Selector 24Vdc

Required Connector Cables J1, J2, J3, RS232

Timing Cal Connector

Exhaust TemperatureBreakout

Connector B Connector A



Engine Panel Sensor Locations

Instrument Panel

Turbo OutletPressure Sensor

Turbo Inlet LeftPressure Sensor

Speed/TimingSensor

AtmosphericPressureSensor

Oil PressureSensor

Turbo Inlet RightPressure Sensor

Jacket-WaterTemperature Sensor

CrankcasePressureSensor

Throttle

Load

Crank

IgnitionEtherManual

Not Used

Tachometer



Electrical Control System Diagram

Electronic UnitInjectors (8)

TPC Service Probe AccessOil Pressure Sensor (filtred)

Turbo Outlet Pressure Sensor

Right Turbo Inlet Pressure Sensor

Left Turbo Inlet Pressure Sensor

Speed/Timing Sensor

Crankcase Pressure Sensor

Left Turbine Inlet ExhaustTemperature Sensor

Right Turbine Inlet Exhaust

Jacket-Water Temperature Sensor

Atmospheric Pressure Sensor

Temperature Sensor

Electronic ControlModule

Disconnect Seitch

- 24V+

Vehicle

Main PowerRelay

Ground Bolt

EngineEngine Control15A Breaker

CAT Data Link

VehicleHarness

Keyswitch

Service Tool

Ether Manual Switch

Ether HoldRelay

Ether StartRelay

Harness

P26

P22/J22

P23/J23

P25/J25

P28/J28

P20/J20

P29/J29

J30/P30

J31/P31

J21/P21

P27/J27

J36/P21 J37/P37



Using the 3500B Training Aid Application

The 3500B Training Aid is intended to be used with the Caterpillar Electronic Service Tool for full functionality.

Automatic Ether InjectionOn the 3500B engine, automatic ether injection is controlled by the ECM. The ECM monitors engine coolant temperature and determines when to inject ether. Drivers in the ECM are used to control relays that provide the high currents needed to activate the ether injection solenoid.

Injector Electronic Trim3500B engines are equipped with an injector electronic trim feature. When an injector is installed in the engine, the mechanic can read a four digit trim code on the injector tappet and enter the code into the ECM using an Electronic Service Tool. The ECM can then optimize injection for that particular injector.

Programmable Monitoring SystemSome 3500B engines include a programmable monitoring system feature. The ECM can monitor parameters and provide warnings, engine derates, and engine shutdowns depending on the status of the parameter. An ET service tool can be used to view and change the monitoring system settings. Usually there will be factory password security on some monitoring system parameters, but for the purpose of this 3500B Training Aid, the security has been disabled.

Crankcase Pressure MonitoringOn 3500B engines, the ECM can monitor absolute crankcase pressure. Atmospheric pressure is then subtracted from absolute crankcase pressure to get gauge crankcase pressure. Gauge crankcase pressure is then used to trigger engine warnings, derates and shutdowns. In general, high crankcase pressure could indicate a problem with the engines pistons, rings, or liners.

Exhaust Temperature MonitoringOn 3500B engines, the ECM directly monitors the exhaust to turbo temperatures for each bank of cylinders (left and right). Exhaust temperatures are then used to trigger engine warnings, derates and shutdowns. High exhaust temperatures are usually the result of high altitude running or excessive inlet air restriction.

Demonstrating 3500B Engine Features



Using the Sensor OverridesSensor override slider controls are provided on the 3500B Training Aid Simulator screen. These overrides are used to set sensor values to higher or lower than normal settings. The slider controls can be accessed by pressing the Manual Sensor Override button on the Simulator screen. A window will appear that allows you to adjust oil pressure, coolant (Jacket Water) temperature , right and left exhaust temperature and crankcase temperature. The window can be closed and the override will remain active if Override Values is enabled. The Manual Sensor Override button turns red when any sensor is overridden.

Automatic Ether InjectionThe automatic ether injection system is simulated on the PC screen with a picture of the two control relays and a picture of the ether solenoid andbottle. When the ECM energizes the relays to inject ether, the relays and solenoid on the PC screen turn red.

The ECM will not inject ether unless the coolant temperature is low. To use the sensor overrides to set the coolant temperature low before starting the engine, fol-low these steps:

CloseClearOverride

OilPressure[absolute]

WaterTemp

ExhaustTemp.[R&L]

Jacket CrankcasePressure[gauge]

56.280 102 815[F]

0.14[PSI][PSI] [F]

Override Sensor Values

EtherRelays

Ether

Start

Ether

Hold

Ether Solenoid SystemControl

EtherAuto/Manual

1

0

ManualSensor

Override



1. At the Simulator screen, select ON-SCREEN.

2. Set the Component Panel ignition keyswitch to ON.

3. Click once on the MANUAL SENSOR OVERRIDE button.

The Override Sensors window will appear.

4. In the Override Sensors window, set the coolant temperature to the bottom of the slider control (-40F). Lower temperatures cause the ECM to auto-matically inject ether longer.

5. Depress and release the CRANK button on the keyswitch.

6. Observe the ether relays and solenoid turn red, indicating that they are energized.

7. Once automatic injection is completed, depress and hold the ETHER MANUAL switch to inject more ether.

Injector Electronic TrimElectronic trim codes can be entered for each cylinder using the ET service tool. The Training Aid must be in the Simulator mode with the keyswitch turned ON so the ECM receives power. The ECM will accept trim codes while the engine is running or stopped. Refer to your ET manuals for more information about operating ET and entering injection trim codes.



Programmable Monitoring System

The programmable monitoring system can be viewed and changed during operation of the Training Aid. Depending on the monitoring system settings, the ECM may provide warnings (via ET), derate the engine, or shut the engine down during operation.

The current status of all monitoring system warnings, derates and shutdowns appears near the top of the ET screen as a short text message.

Status MonitorCat Electronic Technician Status

High EngineCoolant Temp

Engine: 3508B Training Aid

Engine: 3508B Training Aid

3508B Training Aid Group 1

13 PSI

1937 RPM1937 RPM

100%

Boost PressureDesired Engine SpeedEngine SpeedFRC Fuel LimitFuel PositionRated Fuel LimitThrottle PositionPercent Load

214

112

77

93

Status Active Codes Logged Codes Configuration Exit

F ile iagnostics nformation ervice tilities Data ink Se tings elpD I S U L t H

roups . . . ore oom In H ld rint

Engine 3508B Training Aid

G M Z o P

Status Monitor



Note that the Low System Voltage warning will always be active due to the 12V system voltage on the Training Aid. This will not cause any operational problems.

You can also view and change monitoring system setpoints for warnings, derates and shutdowns. In the Monitoring System window, click once on a parameter line to select it and click the CHANGE button. A window appears that allows you to change the state, trip point or delay time of the Monitoring System parameter. Then, by using the sensor overrides or other Simulator controls, you can demonstrate various warn-ings, derate and shutdown actions on the 3500B Training Aid.

ExampleYou can override coolant temperature to 103C and then observe the warning appear on the ET screen after a one-second delay. You can also lengthen the delay time.

Cat Electronic Technition- Monitoring System

Status Active Codes Logged Codes Configuration Exit

File iagnostics nformation ervice tilities Data ink Se tings elpD I S U L t H

rint

Engine 3508B Training Aid

PhangeC

Desctiption State Trip Point Delay TimeLow System Voltage

Warn OperatorLow Engine Oil PressureWarn OperatorEngine DerateEngine Shutdown

High Engine Coolant TemperatureWarn OperatorEngine DerateEngine ShutdownLow Engine Coolant TemperatureWarn OperatorEngine OverspeedWarn OperatorEngine ShutdownHigh Air Filter Restriction PressureWarn OperatorEngine Derate

On

OnOnOn

OnOn

OnOn

OnOnOn

On

24 Volts

NoneNoneNone

216 Det F221 Deg F225 Deg F

167 Deg F

2100 RPM2200 RPM

28 H2028 H20

5 Sec

1 Sec1 Sec1 Sec

5 Sec5 Sec5 Sec

5 Sec

0 Sec0 Sec

5 Sec5 Sec

Low System Voltage Warning

Press the Change button tochange a parameter state, trip,point, or delay time.

Documents

CAT 3500b Application Guide