series engines OPERATION TRAINING

1. 3500 B series Engines

2. PRESENTATION ON CATERPILLAR 3500
SERIES ENGINES

3. Leadership does not just
happen
1973 ???
OPEC...
closed

4.  Improve Exhaust emissions
 Fuel economy
 KW outputs
 Monitoring capabilities
 Reliability
 . Durability.
3500 "B" Objective

5. 3500 SERIES EVOLUTION
Yr Product Max Rating
1980 Phase 0 100 kW/cyl.
1985 Phase 1 112.5 kW/cyl.
1988 Phase 2 125 kW/cyl.
1995 B Series 137.5 kW/cyl.
2000 B HD 150 kW/cyl.

6. Primary objectives of 3500 B
development program.
1. Develop an
electronic engine
control platform.
2. Improved
combustion system.
3. Improved specific
output.

7. CUMMINS
20%
OTHERS
28%
MHI
5%
MTU
5%
DETROIT
7%
CAT
35%
Market share 910 - 2000 kVA

8. Introduction to 3500 series B
engines
 3500 SERIES B engines are
controlled, monitored & serviced
using a Microprocessor
Higher Injection pressures
Better combustion chamber design
Best fuel efficiency in its class.
Better response & block loading
capability
Larger and bigger Camshaft.
Seperate circuit after cooling
 Very low emissions.

9. 3500B series engines
We are now offering the engine in three versions
8 cylinder version - 3508
12 cylinder version - 3512.
16 cylinder version - 3516.

10. Ratings
 1000 KVA - 3508 B - 1180
BHP
 1500 KVA - 3512 B - 1756
BHP
 2000 KVA - 3516 B - 2293
BHP

11. 3500 series B electronic architecture
consists of
1. Engine control - ADEM II ( ECM)
2. Monitoring & Instrumentation -
EIP
3. Engine servicing - ET
4. Information management -
PRCM & CCM.

12. Advanced electronics
PCB technology used in the engine
control module has won mentor graphics
award - eight times against some of the
big names in computer and electronics
industry.

13. Electronic Architecture
ECM
E I P
ELECTRONIC
UNIT INJECTORS
ELECTRONIC SENSORS
CCM
PRCM
CAT DATA LINK
Optional

14. Engine control module
 ECM is a totally self
contained computer.
It has its own
internal power.
CPU has two
motorola 68 HC- 11
microcontrollers and
A1 - kb dual port ram
chip, each of 2 MHz

15.  EEPROM - Customer and factory
programmable values.
 EPROM - Software programs.
FLASH EEPROM - Field up load software
program
OPERATING ROM - Library software
programs aboard micro controller.
BATTERY BACK RAM - Logged events &
data recording.
ECM MEMORIES.

16.  Electronic Injectors - Timing
and metering done by the
solenoid.
Solenoid is controlled by the
ECM.
ECM monitors the engine
real time.
Frequency of monitoring is
1/4th of a second.
ECM gives command for the
FUEL SYSTEM OF 3500 B
SERIES

17. ELECTRONIC UNIT
INJECTORS
Electronically controlled
unit injector combines
electronic actuator,
pump assembly and
nozzle into a single
compact unit.
The fuel can be injected
into the cylinder at a
very high pressure to the
tune of 22000 psi.
Fuel is metered by the

18. Timing control by ADEM II
(ECM)
• Timing is varied with
respect to speed ,
load and after cooler
temperature - 4 D
timing map..
• Cold mode strategy
adjusts fuel injection
timing as a function
of jacket water
temperature, engine
speed and injection

24. EUI - Injector Fill
 Without
pressure from
the rocker arm,
a spring keeps
the plunger
retracted
 Fuel flows into
the injector
through the fill /

25. EUI - Mechanical
Stroke
 As the cam
rotates, it
drives the
plunger
downward
 Until the ECM
signals the
start of
injection, fuel
goes out the

26. EUI - Injection
 On a signal
from the ECM,
the solenoid
closes the
poppet valve
 Pressure
elevates at
the tip to the
5,500 psi
needed to
unseat the

27. EUI - Injection
 Fuel continues
to inject until
the ECM
signals the
solenoid to
open the valve
 Injection
timing and
duration is
controlled by

28. SFC CHART
251.4
223.3
215
209.7
203.3
199.9
197.9
196.8
196.5
196.4
196.7
197.2
0
50
100
150
200
250
300 100
90
80
75
70
60
50
40
30
25
20
10
%load
sfc
in
gms/kwh(+/-3%)

29. Fuel Savings - 3500 B
series
Fuel savings - compared
to the competetion 15 -
20 % !!!
THE BEST in its class.
THE RESULT -Customer
laughs all the way to the
BANK.

30. SENSOR
S
 Sensors used on the
engine are Electrical -
either Digital or Analog
 Power Supply is
distributed by ADEM II.
 All Electronic Items
undergo Failure Mode
and Effects Analysis
to ensure very high
reliability

31.  Crankcase pressure sensor.
Coolant temperature sensor.
Filtered fuel pressure sensor.
Unfiltered fuel pressure sensor.
Filtered oil pressure sensor.
Unfiltered oil pressure sensor.
 Speed /timing sensor.
Left turbocharger inlet pressure
sensor
Right turbocharger inlet pressure
sensor.
Turbocharger outlet pressure sensor.
Atmospheric pressure sensor.
Aftercooler temperature sensor.
Right exhaust temperature sensor.
Left exhaust temperature sensor.
SENSORS

32. 3500 B series Engine
Monitoring

33. ELECTRONIC INSTRUMENT
PANEL
EIP consists of the following for the monitoring
of the engine continuously.
1. Gauge clusters
2. Smart electronic monitoring system.
3. Engine control switch
4. Scroll switch
5. Mode selector toggle switch
6. Horn & horn silencer.
Most importantly this panel can be kept even
100 ft away from the engine using extension
cables and mounting hard ware.

34. GUAGE
CLUSTERS
There will be two guage
clusters as standard in the
engine
Each guage cluster will have
four guages for monitoring the
following.
1. Oil pressure
2. Coolant temperature
3. System voltage
4. Fuel pressure.
Oil Pressure
System Voltage
Coolant Temp
Fuel Pressure

35. 5. RH exhaust temperature.
6. LH exhaust temperature.
7. RH air inlet pressure
8. LH air inlet pressure.
9. Fuel filter pressure differential
10. Oil filter pressure differential.
Exhaust
Temp
Fuel Filter
Restriction
Air Inlet
Restriction
Oil Filter
Restriction
GUAGE CLUSTERS

36. SEMS panel has ten LED s
with alaram to alert the
operator of the condition of
the engine :
System shutdown .
System voltage.
Overspeed
Overcrank
Not in auto.
Low oil pressure.
High coolant
temperature
Low coolant
temperature
Engine coolant level
SEMS
PANEL

37. SEMS Panel has a Liquid
Crystal Display or LCD
which can give read out of
engine parameters
MODE -0: Engine speed and
hours of operation
MODE - 1 : Fuel
consumption /hr and
individual values being
displayed by guage modules.
MODE - 2 : Diagonostic
codes
MODE - 3 : Displays the
worst case & Tattle tale.
MODE - 4 : Toggles between
SEMS Panel

38. ENGINE CONTROL SWITCH
ENGINE CONTROL
SWITCH HAS THE
FOLLOWING
SELECTIONS.
OFF/ RESET
AUTO
MAUAL START
COOL DOWN / STOP
AUTO
MANUAL
START
STOP
OFF - RESET

39. Emergency Stop Button and
Alarm/Alarm Silence

40. Start-up Testing

41. CAT DATA LINK
The cat data link is a
proprietory high speed
electronic communication.
Using this link ECM can
share information EMCP
II, PRCM, CCM and ADEM
related service tool.
Maximum total distance
from one end of the link to
the other is 1500 ft (457 m)

42. ENGINE PROTECTION
STRATEGIES
PARAMETERS ALARM DERATE SHUT OFF
ECM VOLTAGE YES
ENGINE OIL PRESSURE YES YES YES
JW TEMPERATURE HIGH YES YES YES
JW TEMPERATURE LOW YES
OVERSPEED YES YES
AIR INLET RESTRICTION YES YES
ALTITUDE DERATION YES
EXH. TEMPERATURE YES YES
OIL FILTER DIFFERENTIAL YES
FUEL FILTER DIFFERENTIAL YES
CRANK CASE PRESSURE YES YES YES
AFTER COOLER TEMP HIGH YES YES

43. CAT Electronic Technician
 By using this computer
based service tool the
3500 series B
electronics can be
easily accessed. CAT
ET provides real time
access
 ET can also capture the
engine operating
conditions just before
the fault condition.
 ET is also self
diagnosing, it is able to
detect the correctness

44. Customer Programmable
Functions
Accelaration delay on start up.
Accelaration ramp time.
Cooldown /shut down
Auto crank cycle time
Crank terminate.
Here the customer can alter the default
settings of the engine to suit his
convenience with a service tool only. No
password required.

45. Low emission diesel
30% average
improvement
5-8 g/bhp-hr
depending on SCAC
strategy
Improved fuel
economy
Improved transient
response
Less transient smoke
Emissions

46. New Emission Draft Laws
Smoke
Limit
Nox HC CO PM
1.7.2003 9.2 1.3 5 0.6 0.7
1.7.2004 9.2 1.3 3.5 0.3 0.7
1.7.2003 9.2 1.3 5 0.5 0.7
1.7.2004 9.2 1.3 3.5 0.3 0.7
>50kwupto
260 kw 1.7.2003 9.2 1.3 3.5 0.3 0.7
>260kw upto
800kw 1.7.2004 9.2 1.3 3.5 0.3 0.7
>19kw upto
50kw
Rating
Date of
Impleme
ntation
Emission limits(g/kw-
hr) for
upto 19kw

47. Remote Communications

48. PROGRAMMABLE RELAY CONTRO
MODULE.(OPTIONAL)
By using PRCM, information
through CAT data link can be
used to activate standard
relay contacts.
This has seven standard
relays and it can be expanded
upto total 25 relay contacts.
Since it is programmable,
operator can select from over
53 functions, which to
annunciate.
PRCM
SEVEN RELAYS
LEDS

49. ECM
PRCM
CAT DATA LINK
DIGITAL SIGNALS
RELAY OUTPUTS
RELAY
RELAY
DATA LINKS
UPTO 1000 FT OR 305 M
9 DRY CONTACTS
9 DRY CONTACTS
PROGRAMMABLE RELAY CONTROL
MODULE (OPTIONAL)

50. CAT DATA LINK
DATA LINKS
UPTO 1000 FT OR 305 M
CCM
MODEM
SATELLITE
PERSONAL
COMPUTER
PERSONAL
COMPUTER
Module(Optional)
ECM

51. Genset Data Links
CAM
CIM
Alarm Modules (six options)
CCM ADEM
Remote
RDM
Note: Maximum of 3 Modules
on Serial Data Link
Serial Data Link
(two conductor,
1000 feet max.
from GSC)
Generator Fault
Relay Output to
Breaker Shunt trip Over current/
Over Voltage
Relays
RS 232
Interface
(40 feet
max.)
Cat Data Link
(two conductor,
1500 feet max.)

52. CYLINDER
BLOCK
High Tensile strength
block - better strength &
Rigidity.
Top Deck Cooling Shelf
- Optimized heat
transfer & Cool
operation and long
Engine life
Access covers on block
with out board split

53. Articulated
Pistons
 These engines uses two
piece articulated piston
consisting of forged steel
crown and a cast
aluminium skirt.
This two part design
provides excellent piston
strength and reduced
weight while allowing for
closer fit to the cylinder
liner and reducing noise
from piston slap.
These pistons also

54. Larger Camshafts
 Cam shaft major bearing diameter from
85.9 mm to 91.9 mm to allow for more
aggressive lift ramp on injector lobe.
 Cam base circle and un machined core
diameters are increased to the maximum
diameter possible.
 To accomadate higher valve train loads ,
all lifters feature a larger diameter roller
pressure lubricated . helper spring
provided for better stability.

55. R
A
D
I
A
T
O
R
 Lower fuel consumption and low
emissions, controlling the after cooler
temperature either to 30 deg C or 60
deg C or 90 deg C, irrespective of
ambient temperature.
Seperate Circuit After
Cooling (SCAC)
ENGINE
AFTER COOLER
P
P
A
C
R
A
D

56. 3500 B - Transient
Response
Transient Response
30
35
40
45
50
55
1 2 3 4 5 6 7 8 9 10 11
Time(secs)
Freq.(Hz)
(secs)
3516 B
3516
Transient response is
excellent due to :
Higher injection
pressures
Improved combustion
chamber design.
Better atomisation.
Variable timing.
Dual turbo - low
inertia matched
turbos

57. Service is the Difference

58. Partners in Power
Power Partners should have
complimentary capabilities and
organizations. Choosing the correct
partner is the key to the long term success