Cat 3500b Application Guide g321b

3500B Application Guide

3500B Basic Engine The 3500B Basic Engine application is a software training module for the Caterpillar Engine Simulator’s 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 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 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

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 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 engine’s 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

0

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 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 (-40°F). 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 103°C 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