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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