3500B
Application 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.
The Caterpillar Engine Simulator 3500B-1
3500B Application
Application Information
EUI System Specs
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
ECM Harness Port Connections
Exhaust Temperature
Breakout
Connector B
Connector A
Timing Cal Connector
The Caterpillar Engine Simulator 3500B-2
3500B Application
Application Information
Engine Panel Sensor Locations
Jacket-Water
Temperature Sensor
Speed/Timing
Sensor
Turbo Outlet
Pressure Sensor
Atmospheric
Pressure
Sensor
Turbo Inlet Left
Pressure Sensor
Oil Pressure
Sensor
Crankcase
Pressure
Sensor
Turbo Inlet Right
Pressure Sensor
Instrument Panel
Tachometer
Ether
Manual
Not Used
Load
Throttle
Ignition
Crank
The Caterpillar Engine Simulator 3500B-3
3500B Application
Application Information
Electrical Control System Diagram
Electronic Control
Module
Disconnect Seitch
Electronic Unit
Injectors (8)
24V
+
P26
TPC Service Probe Access
Oil Pressure Sensor (filtred)
P22/J22
Turbo Outlet Pressure Sensor
P23/J23
Engine Control
15A Breaker
Right Turbo Inlet Pressure Sensor P25/J25 Engine
Harness
Left Turbo Inlet Pressure Sensor
P28/J28
Speed/Timing Sensor
P20/J20
Crankcase Pressure Sensor
P29/J29
Left Turbine Inlet Exhaust
Temperature Sensor
J30/P30
Right Turbine Inlet Exhaust
Temperature Sensor
J31/P31
Vehicle
Main Power
Relay
Ground Bolt
Keyswitch
CAT Data Link
Jacket-Water Temperature Sensor J21/P21
Atmospheric Pressure Sensor
Service Tool
Vehicle
Harness
Ether Manual Switch
Ether Hold
Relay
Ether Start
Relay
J36/P21
J37/P37
P27/J27
The Caterpillar Engine Simulator 3500B-4
3500B Application
Application Information
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 Injection
On 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 Trim
3500B 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 System
Some 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 Monitoring
On 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 Monitoring
On 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
The Caterpillar Engine Simulator 3500B-5
3500B Application
Application Information
Using the Sensor Overrides
Sensor 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.
Override Sensor Values
C lose
56.280
[PSI]
102
[F]
Jacket
Oil
Pressure Water
[absolute] Temp
815
[F]
Exhaust
Temp.
[R&L]
0.14
[PSI]
Clear Override
Crankcase
Pressure
[gauge]
Automatic Ether Injection
The 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 and
bottle. When the ECM energizes the relays to inject ether, the relays and solenoid on
the PC screen turn red.
Ether
Relays
Ether Solenoid
System
Control
1
Ether
Start
Ether
Hold
Manual
Sensor
Override
Ether
Auto/Manual
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, follow these steps:
The Caterpillar Engine Simulator 3500B-6
3500B Application
Application Information
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 automatically 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 Trim
Electronic 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.
The Caterpillar Engine Simulator 3500B-7
3500B Application
Application Information
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 Monitor
Cat Electronic
Status
Monitor
F ile Diagnostics I nformation Service
Status
Active Codes
Technician Status
Utilities
Data Link Se t tings Help
Logged Codes
Configuration
Exit
Engine: 3508B Training Aid
High Engine
Coolant Temp
3508B Training Aid Group 1
Engine: 3508B Training Aid
13 PSI
1937 RPM
1937 RPM
214
93
112
100%
77
Groups . . .
M ore
Zoom In
H o ld
Boost Pressure
Desired Engine Speed
Engine Speed
FRC Fuel Limit
Fuel Position
Rated Fuel Limit
Throttle Position
Percent Load
Print
Engine 3508B Training Aid
The Caterpillar Engine Simulator 3500B-8
3500B Application
Application Information
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.
Low System Voltage Warning
Cat Electronic Technition- Monitoring System
File Diagnostics I nformation Service
Status
Active Codes
Desctiption
Low System Voltage
Warn Operator
Low Engine Oil Pressure
Warn Operator
Engine Derate
Engine Shutdown
High Engine Coolant Temperature
Warn Operator
Engine Derate
Engine Shutdown
Low Engine Coolant Temperature
Warn Operator
Engine Overspeed
Warn Operator
Engine Shutdown
High Air Filter Restriction Pressure
Warn Operator
Engine Derate
Utilities
Data Link Se t tings Help
Logged Codes
Configuration
Exit
State
Trip Point
Delay Time
On
24 Volts
5 Sec
On
On
On
None
None
None
1 Sec
1 Sec
1 Sec
On
On
On
216 Det F
221 Deg F
225 Deg F
5 Sec
5 Sec
5 Sec
On
167 Deg F
5 Sec
On
On
2100 RPM
2200 RPM
0 Sec
0 Sec
On
On
28 H20
28 H20
5 Sec
5 Sec
Print
Change
Engine 3508B Training Aid
Press the Change button to
change a parameter state, trip,
point, or delay time.
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 warnings, derate and shutdown actions on the 3500B Training Aid.
Example
You 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.
The Caterpillar Engine Simulator 3500B-9
