Caterpillar

Engine Simulator
User’s Guide
 Technical Support

Technical Support
For technical support, contact Techcom, Inc.
Simulator Technical Support at:

Phone 317-898-2721
Fax 317-898-0771
E-mail [email protected]

The Caterpillar Engine Simulator

 Table of Contents

Chapter 1: Before you begin 1-1

Caterpillar Engine Simulator documentation 1-3

About this manual 1-3
Some basic Windows characteristics 1-4
Registering your Caterpillar Engine Simulator 1-4

Chapter 2: Setting up your system 2-1

Unpacking the Simulator 2-2

System requirements 2-3
Quick setup 2-4
Setting up your hardware 2-6
Powering and starting the system 2-11
Installing ETA software 2-12

Chapter 3: System operation & quick tutorial 3-1

Starting up 3-3
Accessing the ETA software 3-7
Setting up a problem 3-8
Saving problems 3-13
Generating more problems 3-13
Compiling problems into a lesson 3-14
Saving the lesson 3-15
Editing the lesson 3-16
Preparing the student exercise 3-17
Changing your password 3-18
Shutting down the ETA 3-19

Chapter 4: Training on the Simulator 4-1

The Engine Component Panel 4-3

The on-screen functions 4-5
Connecting ECAP 4-6
Connecting the Timing Calibration Jumper 4-7

The Caterpillar Engine Simulator i

Appendixes: A-1

Appendix A: Setting up user-supplied computers A-1

Appendix B: Programming the ECM B-1
Appendix C: Menu maps C-1

Application Guides: 3176B-1

3176B Marine Application 3176B-1

3406E On-Highway Truck 3406E-1
769D Off-Highway Truck 769D-1
777C Off-Highway Truck 777C-1
785B Off-Highway Truck 785B-1
789B Off-Highway Truck 789B-1
793B Off-Highway Truck 793B-1
D11N Track Type Tractor D11N-1
3500BBasicEngine

The Caterpillar Engine Simulator ii

 1 Before you begin

Caterpillar Engine Simulator documentation 1-3

About this manual 1-3

Some basic Windows characteristics 1-4

Registering your Caterpillar Engine Simulator 1-4

The Caterpillar Engine Simulator 1-1

 1 Before you begin

Welcome to the Caterpillar Engine Simulator. This system is an electronic

engine training aid designed to provide realistic electronic simulation of
engine malfunctions and troubleshooting. Actual engine hardware and
specially designed software let maintenance personnel use diagnostic tools
to troubleshoot “real” engine performance discrepancies induced by the
instructor. These procedures help students understand troubleshooting
methods and master diagnostic techniques. More importantly, using this
Simulator allows the students to move confidently from the classroom to the
field environment. The Simulator is an essential part of the training program.

The Caterpillar Engine Simulator consists of an Engine Component Panel

(Simulator) and Electronic Training Aid© (ETA) software. Together, the ETA
and the component panel provide a host of features not easily available on
actual equipment.

• Instructor can quickly set up “mock” electronic engine failures, save them
as problems, and then compile problems into lessons.
• Problems generated on the ETA affect the component panel’s sensors,
gauges, lamps, ECM and other active devices.
• Students can easily bring prepared problems to the computer screen and
troubleshoot them from the component panel.
• Electronic Service Tool such as Electronic Technician (ET) or Electronic
Control Analyzer Program (ECAP) can be used with the Engine Compo-
nent Panel.

The Caterpillar Engine Simulator permits effective training for technicians

without the cost, noise, size and pollution of an actual engine. Technicians
can learn real troubleshooting procedures on the Simulator and later apply
that knowledge to an actual engine.

The Caterpillar Engine Simulator 1-2

 Before you begin
Caterpillar Engine Simulator documentation
Caterpillar Engine Simulator documentation
This manual describes the simulator and how to make it an effective tool in
your Caterpillar training. It will take you through the following points to get
you up and running.

• “Setting up your system” covers the physical set up of the Engine

Simulator equipment, from connecting cables to turning on the system.
• The “System operation & quick tutorial” runs you through the entire ETA
program, from designing a sample problem and lesson to preparation for
the student. It also explains, in detail, the procedures for opening the ETA
program, viewing the on-line application reference screens, and creating
and saving problems and lessons.
• “Training on the Simulator” is a detailed description of the procedures for
conducting a training lesson on the Caterpillar Engine Simulator.
• Application software and an “Application Guide” accompany each
application.
• The Application Guide supplies instructions, specifications and
information unique to that application.

About this manual

Your Caterpillar Engine Simulator User's Guide provides information on
setting up, installing, and running the Caterpillar Engine Simulator and its
Electronic Training Aid program. This manual is constructed with the
assumption that the user is familiar with the personal computer (PC) and
Windows™ environment. If not, you should learn the basics from the
hardware and software documentation supplied by the computer
manufacturer.

Steps that you perform are numbered (1, 2, 3, etc.). Text that you enter into
the computer is in this FONT.

Caterpillar Engine Simulator system can be set up using the “Quick setup”
procedures outlined in the following steps. However, you should go through
the full installation process described in Chapter 2 to ensure correct
installation of the Simulator.

The Caterpillar Engine Simulator 1-3

 Before you begin
Some basic Windows characteristics
Some basic Windows characteristics
While working in the Windows environment, you will notice that many
programs share common shortcut commands. This is also true with the ETA
program. For example, notice that each menu name has a letter that is
underscored. Hold down the Alt key and press the underscored letter to open
the menu.
Press Alt+F to
open the File
menu. Then
press the letter
C on your
keyboard to
select the
Choose Lesson
command.

Once you open the menu, select the desired menu command by pressing the
underlined letter.

Also, if the menu command has a figure like F3 or Shift+F5 beside it, this
command can be executed without opening its menu; just press the
appropriate keys. Some buttons in the ETA can be activated by using keys on
the keyboard instead of the mouse.
You can click on
the button with the
mouse, or hold
down on the Alt key
Buttons like these can be and press the
pushed by holding the Alt underlined letter to
key and pressing the execute any of
underlined letter. these commands.

Physical Panel On Screen

Consult the Windows user’s guide to answer any other questions you have
regarding the Windows environment.

Registering your Caterpillar Engine Simulator

Please take time to fill out the registration card included with this shipment
and mail or fax it to Techcom, Inc. 8909 East Boehning Lane, Indianapolis,
Indiana 46219, USA. If you require additional upgrades to your software or
components, please make note of these on the registration card. If you need

The Caterpillar Engine Simulator 1-4

 Before you begin
Registering your Caterpillar Engine Simulator
components, please make note of these on the registration card. If you need
additional registration cards, make a photocopy of the registration page in
this chapter.

Also fill in the information on the registration page in this chapter and retain
it with this manual. For technical support, we will need the details about
your system.

After your registration card is received, the information will be entered in

our system to recognize you as a licensed Caterpillar Engine Simulator
owner. As a registered owner, you will receive free technical support and
software updates for the core ETA software, for one year from the date of
purchase. You are also entitled to 90 days of free technical support and
software updates for application and supplemental software.

Note: Important software updates, parts and information will be sent to the
name listed on the registration card. Make sure the name and address on the
registration card is complete.

The Caterpillar Engine Simulator 1-5

 Caterpillar Simulator Registration Card
Please complete this information about your Caterpillar Simulator.
Include information about Simulators that are not already regis-
tered. When you are registered, you will be eligible to receive soft-
ware updates and technical support. Make sure you accurately fill
in the name of the party responsible for receiving all materials
concerning the Simulator.

Name _______________________________________
Title _________________________________________
Company _____________________________________
Phone # _____________________________________
Fax # ________________________________________
Address _____________________________________
City _________________________________________
State ________________________________________
Country _____________________________________
Date Received_________________________________
Simulators & Serial Numbers ____________________
_____________________________________________
_____________________________________________
_____________________________________________
Computer Model Number _______________________
Computer Serial Number ________________________
Monitor Serial Number__________________________

How to register is your card is missing from your shipment:

1. Complete the information blanks on this page.
2. Photocopy the completed page.
3. Return the completed page to this manual for future technical reference.
4. Mail the photocopy to:
Techcom, Inc., 8909 E. Boehning Ln., Indianapolis, IN 46219, USA
or fax the photocopy to 317-898-0771.
2 Setting up your system

Unpacking the Simulator 2-2

System requirements 2-3

Quick setup 2-4

Setting up your hardware 2-6

Powering and starting the system 2-11

Installing ETA software 2-12

The Caterpillar Engine Simulator 2-1

 2 Setting up your system

The following pages explain how to unpack and install the Caterpillar Engine
Simulator. We recommend that you closely follow the unpacking procedure to
make sure the Simulator package is complete. However, if you have set up the
system before and are comfortable with the system design, you may use the
“Quick setup” directions.

If you are supplying your own computer, refer to Appendix A.

Unpacking the Simulator

Carefully unpack your Caterpillar Engine Simulator as follows:

1. Remove the wing nuts, washers, and screws that secure the top and front
of the Simulator shipping crate. Remove the top and front of the crate and
place them aside.
2. Carefully remove the monitor, keyboard, computer, and any other item
from the removable tray. Lift the tray from the shipping crate. Save the
tray for reuse.
3. With an assistant, grasp the Engine Component Panel by the handles on
the side and lift it from the crate. Place it on the floor on its base.
4. Return the tray, top cover and front cover to the crate and secure with the
screws, washers, and wing nuts. Store the shipping crate and packing
material for future use.

The Caterpillar Engine Simulator 2-2

 Setting up your system
System requirements

The Simulator package contains the following components:

• Computer, monitor, keyboard, mouse, necessary cables and cords, and

manufacturer’s documentation (Optional)
• Connector box and its cables and cards (pre-installed on systems with
computers; loose on systems without)
• Electronic Training Aid program on 3.5” disks (loaded on systems with
computers)
• Engine Component Panel
(1) 36-pin Cable - Code J1
(1) 50-pin Cable (male connectors) - Code J2
(1) 50-pin Cable (female connectors) - Code J3
(1) 9-pin Cable - Code RS232
(1) AC Power Cord
(1) Timing Calibration Connector
(4) 1/4” x 4” ECM Mounting Studs
(4) Spacers
(4) 1/4” ECM Mounting Nuts

System requirements
If you provide the computer for your Simulator, the computer must meet the
following requirements:

• An 80486 CPU computer or higher, with at least 8 MB of RAM

• A hard disk with 10 MB of free space
• A 3.5” floppy disk drive
• A VGA Monitor
• Windows 3.1 installed, running in 386 enhanced mode or Windows 95
• DOS 5.0 or higher
• A mouse compatible with Windows 3.1
• Four (4) or more available ISA slots

The Caterpillar Engine Simulator 2-3

 Setting up your system
Quick setup

Quick setup
Note: For a detailed setup see “Setting up your hardware” later in
this chapter.

1. Connect the monitor, keyboard, and mouse to the computer according to

the manufacturer’s instruction. If you provide the computer for your
Simulator, see “Setting up user-supplied computers” on page 1 of
Appendix A before going any further.
2. Connect the RS232 cable to the active serial port on the back of the
computer. Connect the other end to the RS232 Port on the back of the
Engine Component Panel.

J1 cable RS232
Cable
J2 cable

J3 cable

3. Connect the Engine Component panel to the gray connector box with
the J1, J2, and J3 (J4 and J5 if used) cables.

J2 cable

J1 cable

J3 cable

4. Mount the 8-cylinder ECM to the Engine Component Panel. On

16-cylinder ECMs, install the appropriate personality module before
mounting. Note that the ECM spacers and bushings are Caterpillar parts.

The Caterpillar Engine Simulator 2-4

 Setting up your system
Quick setup

5. Program the ECM for the desired application before simulating.

Note: The ETA program cannot communicate with an ECM unless it

has been preprogrammed for the new application. If you aren’t sure how
the ECM is programmed, check it with Electronic Service Tool. If you
need to program your ECM, refer to “Programming the ECM” in
Appendix B.
6. Switch the 12- and 24-volt ECM Power Selector on the back of the
Engine Component Panel to the correct power setting for the current
ECM and application.
The ECM Power Selector Set Voltage Selection
must be set to the switch to local voltage.
specification in the

WARNING
Do not connect electrical power to the
computer or the Simulator until the
setup procedure is complete. Failure to
do so could result in electric shock or
damage to equipment.

7. Make sure the Voltage Selection switch on the Engine Component Panel
matches local voltage (115 or 230 volts).

The Caterpillar Engine Simulator 2-5

 Setting up your system
Setting up your hardware

Note: The red voltage switch is visible through one of the two labeled
holes on the back of the panel. If it does not match the local voltage,
remove the back from the component panel, locate the Voltage Selection
toggle switch and move it to the correct voltage.
The Voltage
Selection switch
is accessible by
opening the back
of the component
panel.

Remember:
The power to
the component
panel must be
disconnected
before opening
the back.

8. Make sure that all power switches are OFF. Connect power to
the system.
9. Turn ON the computer and start Windows.
10. The Electronic Training Aid is in the “ETA” group of Window’s
Program Manager.

Setting up your hardware

Before setting up your Caterpillar Engine Simulator, make sure the area in
which you will be working is near a grounded power source. The system
must be placed on a sturdy surface, capable of holding more than 175 lbs.
Also, there should be clear access to the rear of the Engine Component Panel
and the computer.

Follow these instructions to set up your system:

1. Connect the monitor, keyboard, and mouse to the computer according to

the manufacturer’s instructions. Refer to the user documentation
shipped with the computer to locate the correct ports and cables for a
proper hookup.
If you supply your own computer, see “Setting up user-supplied com-
puters” in Appendix A before going to the next step.
2. Position the Engine Component Panel so the connector ports are within
five feet of the gray connector box on the computer.

The Caterpillar Engine Simulator 2-6

 Setting up your system
Setting up your hardware

3. Connect the 9-pin RS232 cable to Serial Port 2 on the back of the com-
puter. Connect the other end of the cable to the RS232 Port on the back
of the Engine Component Panel.
Use the 9-pin serial cable to connect the
computer to the component panel.

Note: The ETA program is configured to make Serial Port 2 as the

active port for communication with the Engine Component Panel. Refer
to the computer manufacturer’s documentation to identify Serial Port 2
on the back of your computer.
4. Locate the gray connector box on the side of the computer. Layout the
J1, J2, and J3 cables between the Engine Component Panel and the com-
puter. The ports on the gray connector box and the ports on the Engine
Component Panel are clearly labeled.
5. Install the J1 cable connector in the J1 port on the gray connector box,
securing it with the safety clips on the port.

Use the J1, J2, and J3 cables

to connect the computer to the
component panel.

blkbox.tif

6. Insert the other end in the J1 port on the back of the Engine Component
Panel. Secure the connector with the safety clips.

The Caterpillar Engine Simulator 2-7

 Setting up your system
Setting up your hardware

7. Repeat the procedure with J2 and J3 (J2 and J3 are opposite-gendered to

prevent incorrect connection). J3 is secured to the connector box and
Engine Component Panel ports with screws.

8. Install your ECM unit. Mount the ECM to the Engine Component Panel
as shown below. Note that the rubber grommet and bushing are not
supplied with your Simulator. You should find these items with your
ECM mounting set.

ECM Mounting Kit:

1. 1/4" nut Supplied (4)
2. Stud-1/4" x 4" Supplied (4)
3. Rubber Grommet Pt. # 9X9896 (8 req.)
4. Bushing Pt. # 9X9838 (4 req.)
5. Spacer Supplied (4)

Caution: Do not overtighten the nut!

Note: If the application uses an ADEM I ECM, install the personality
module into the back of the ECM before mounting the ECM. If the
application uses an ADEM II ECM, install the personality module into
the front of the ECM.
9. Connect the ECM to the Engine Component Panel with the appropriate
wiring harness. Your Application Guide provides information on which
wiring harness to use.

The Caterpillar Engine Simulator 2-8

 Setting up your system
Setting up your hardware

10. Remove and store protective caps from only the connector ports that
will be used.

CAUTION
Do not touch exposed pins in the
connector ports. It may damage
the equipment’s electrical system.

11. Insert the ECM end of the harness into the ECM port. Now, notice that
the ports on the Engine Component Panel are marked A and B. Refer to
the Application Guide to determine the port or ports to be used for the
application you will be running. Insert the Engine Component Panel end
of the harness into the appropriate port.

Component Panel
Connectors

ECM Connector

harness.tif

Secure the
harness con-
nectors to the
ports with an
Allen wrench

12. Secure the connectors to their ports with the 4mm Allen head screws in
the connectors.

Note: Program the ECM after the setup is complete, and before starting
the Caterpillar Engine Simulator. See “Programming the ECM” in
Appendix B.

The Caterpillar Engine Simulator 2-9

 Setting up your system
Setting up your hardware

13. Make sure the ECM Power Selector on the back of the Engine Compo-
nent Panel is set according to the Application Guides’ specifications.

14. Make sure the Voltage Selection switch on the back of the Engine Com-
ponent Panel is set for the local voltage, 115 or 230 volts (50 or 60 Hz).
The Voltage
Selection switch
is accessible by
opening the back
of the component
panel.

Remember:
The power to
the component
panel must be
disconnected
before opening
the back.

WARNING
Disconnect electrical power before removing the
back cover. Failure to do so could result in severe
personal injury and or equipment damage.

15. To change the Voltage Selection switch position, remove the back cover
and switch the Voltage Selection switch to the correct voltage. Replace
the back cover
16. After completing the preceding steps, check that all cables are properly
connected to the correct ports and are secured with safety clips or screws.
17. If the computer and control panel are linked correctly, you can now pro-
gram the ECM for the specific application. See “Programming the
ECM” on page 1 of Appendix B.

The Caterpillar Engine Simulator 2-10

 Setting up your system
Powering and starting the system

Powering and starting the system

Connect power and start the Caterpillar Engine Simulator as follows:

1. Switch the 12-24V ECM Power Selector on the back of the Engine
Component Panel to 12V or 24V, whichever is required by the installed
ECM (refer to the Application Guide).

Refer to the Application

Guide for the correct ECM
voltage setting.
panlback.dfx

2. Make sure the 115V or 230V Voltage Selection switch is positioned on

the local voltage.
The Voltage
Selection switch
is accessible by
opening the back
of the component
panel.

Remember:
The power to
the component
panel must be
disconnected
before opening
the back.

3. Make sure all computer and Engine Component Panel master power
switches are in the OFF position.
4. Connect the computer and Engine Component Panel power cables to a
grounded AC power source.

The Caterpillar Engine Simulator 2-11

 Setting up your system
Installing ETA software

Installing ETA software

To upgrade or install the ETA software from the installation diskettes:

1. Turn on the computer and start Windows.

2. Insert Disk 1 in your 3.5" disk drive.
3. Choose File from the Windows Program Manager (Windows 95 users
click the Start button).
4. Choose Run.
5. Type either A:\SETUP or B:\SETUP (depending on your computer’s
configuration).
6. Choose OK.
7. Follow the on-screen instructions.

The Caterpillar Engine Simulator 2-12

 3 System operation &
quick tutorial

Starting up 3-3

Accessing the ETA software 3-7

Setting up a problem 3-8

Saving problems 3-13

Generating more problems 3-13

Compiling problems into a lesson 3-14

Saving the lesson 3-15

Editing the lesson 3-16

Preparing the student exercise 3-17

Changing your password 3-18

Shutting down the ETA 3-19

The Caterpillar Engine Simulator 3-1

 3 System operation &
quick tutorial

The Electronic Training Aid software (ETA) is a Windows™ based program

that simulates various electronic signals from an electronically controlled
Caterpillar vehicle. The ETA allows the operator to customize these signals
to appear to be electrical faults. The changes can then be recorded and
played back for the student to troubleshoot. Additionally, the ETA provides a
simulated dashboard for any application, complete with moving gauges
and functioning signal lamps and various engine controls.
The ETA program operates with minimal learning time and requires very
little data input. An Information Mode provides the student and instructor
with instant access to on-line information about an engine and application.
The engine’s electronic components are covered in detail with front, back
and side views of the engine and a detailed system diagram. Navigating
through the Information Mode is as easy as clicking the mouse button.
Instructor screens make setting up and compiling problems into lessons a
simple process. You can set up problems in the Problem Editor, one of the
instructor screens. The Problem Editor holds a list of electronic engine com-
ponents and possible fault condition switches. In this screen you can select a
component and custom design its fault. You have control over the type of
fault and the timing of the fault. One or more faults are saved as a problem.
The Lesson Editor is another instructor screen that lets you view problems
you have created, and compile them into training lessons. Your lessons can
include random problems or problems based on a certain theme. Existing
lessons also can be edited from this screen.
Students open lessons from the ETA’s Simulator screen. When a problem
is active, relays physically open, or short, wires to create realistic faults.
Students can manipulate engine speed, load, and gear position from the
ETA’s Simulator screen, and use regular troubleshooting techniques to find
the fault on the Engine Component Panel. The student can move from
problem to problem from the ETA’s Simulator screen.
The following tutorial will give you basic information on composing simple
problems using the Problem Editor, grouping the problems into training
lessons using the Lesson Editor, and starting a training lesson from the
Simulator’s dashboard, the ETA Simulator screen. You will use the 777C
Off-Road Truck application for this tutorial.
The Caterpillar Engine Simulator 3-2
 System operation & quick tutorial
Starting up

Note: The following instructions were written with the assumption that you
are familiar with the DOS and Windows environment. If you are not, refer to
the manufacturer's reference documentation.

Starting up
1. Turn on the PC and start Windows. Refer to your manufacturer’s
documentation.
Note: The ETA program can operate only in Windows. If Windows
does not automatically come up when you turn on the computer,
type the word WIN after the C:\> prompt. Example: C:\>WIN.
Then press Enter.
2. Turn on the Engine Component Panel Main Power.
3. Place the Ignition ON/OFF selector switch on the component panel in
the ON position.
4. If using Windows 3.1, start the ETA program by double-clicking the left
mouse button on the ETA icon.

ETA
ETA Icon
Click twice to
open program.
ETA 2.11 Diagnostics Release Notes

The ETA icon is located in the Electronic Training Aid group, which is
found in Windows’ Program Manager.
To start the ETA program using Windows 95, click the Start button,
point to Programs, point to ETA, then click on the application with the
left mouse button.

The Caterpillar Engine Simulator 3-3

 System operation & quick tutorial
Starting up

5. Click OK to continue past the About Electronic Training Aid screen.

6. Select the 777C Off-Highway Truck application by clicking on it once

and then clicking the OK button.

Select the
application.

Note: If an error message appears, it means the computer failed to com-

municate with the ECM. Various situations may cause this to occur:
• The Main Power switch is not ON.
• The Ignition switch is not ON.
• The ECM was installed incorrectly.
• The ECM was programmed incorrectly.

The Caterpillar Engine Simulator 3-4

 System operation & quick tutorial
Starting up

Select Abort, Retry, or Ignore from the Error message box.

Select Ignore to open Select Retry to attempt Select Abort to return

the application with-out to open the application. to the ETA Introductory
using the component screen.
panel.

Select Retry to...

To run ETA with the Engine Component Panel, place the engine Main
Power ON/OFF and Ignition ON/OFF switches in the ON position, and
then select Retry.
Select Ignore to...
To run ETA without the component panel, select Ignore. You may
choose to do this when creating training problems and lessons.
Select Abort if...
If the ignition switch is turned on and you are unsure why the computer
cannot communicate with the ECM, select Abort to return to the
Application Introductory screen. Check your hardware setup,
particularly the RS-232 cable.
If the application does not match the ECM application, a Personality
Mismatch Error will appear. This means that the personality module in
the ECM does not match the selected application.

Once the application is loaded into the computer’s memory, the

Application Introductory screen appears. From this screen, you can go
directly to the Simulator program, or you can view the application’s on-
line reference information.

7. View the on-line reference material.

The Caterpillar Engine Simulator 3-5

 System operation & quick tutorial
Starting up

ETA On-line Reference Information

The ETA’s On-line Reference Information is like a technical manual on the
computer. You turn the “pages” by clicking buttons and highlighted subject
headings, which are linked to pages with more information. On-line refer-
ence information works much like Windows’ help option (F1).

On the Application Introductory screen, click on Information to view the on-

line application information options. This basic reference material is avail-
able to the instructor and students for viewing at any time during program
operation.

Select
Information to
view on-line
application
The option information.
boxes
open
information
screens Click on Back to
according return to previous
to the screens.

Engine Information
Engine Information includes a visual description of the engine’s
electrical components and their location on the engine. You can
choose between front, rear, and side views of the engine.
Application Information
Application Information reveals information on electrical components
that relate to the selected application. Select this option to view the
whole Engine Component Panel and its active sensors, switches, and
harness ports for the loaded application.
System Diagram
System Diagram lists and describes all the EUI system components.
This selection also displays a wiring diagram for the application
and engine.
For this tutorial, select Engine Information.
Click on green text to see a detailed description of that component.
Choose Back to return to the previous screen. Continue selecting Back
until you reach the Application Introduction.

The Caterpillar Engine Simulator 3-6

 System operation & quick tutorial
Accessing the ETA software

Accessing the ETA software

1. Select Simulator to go to the ETA Simulator screen.
The Dashboard for the 777C Application.
This screen has functioning gauges, warning lamps, throttle and load controls, and
operating switches.

This is the central screen from which you will access the tools you need
to set up training lessons. Additionally, this screen is used by students to
complete training exercises.
2. Turn ON the On-Screen switch to begin working from the computer.
The On-Screen setting allows you to operate the Caterpillar Engine
Simulator from the computer. The On-Screen/Physical Panel affect the
following Simulator features:
• Throttle
• Load
• Start button
• Switches (four toggles)
The Physical Panel setting overrides the computer controls and allows
you to manipulate Engine Speed, Load and other controls from the
Engine Component Panel, which is useful while the student is trouble-
shooting a problem.
3. Put the gear selector in Neutral. Use the selector on the screen or on the
physical panel.

The Caterpillar Engine Simulator 3-7

 System operation & quick tutorial
Setting up a problem

4. Press the Start button to crank the engine. When you crank the engine,
the injectors fire (this is indicated by the flashing red lights on the Com-
ponent Panel) and the gauges become active, just as they would on an
actual engine.
5. If you wish to disable the EMS alarm, click on Sound in the File>Prefer-
ences menu (a check mark indicates the sound is on).

Setting up a problem
The Electronic Training Aid is divided into three modes through the Window
menu. The instructor has access to the Problem Editor and the Lesson Editor.
Both the student and instructor have access to the ETA’s Simulator screen.
The following example will instruct you on how to set up an actual problem,
save it, and compile it as a lesson.

Problems can consist of one or more fault conditions, but in this case we will
create a single fault condition.

1. In the Simulator screen, open the Window menu by clicking on it once.

Choose Problem Editor.

Select Problem
Editor by clicking
it or pressing
Control P.

This is an instructor mode so it has the password protection option.

The Caterpillar Engine Simulator 3-8

 System operation & quick tutorial
Setting up a problem

2. If you have not created your own password, click OK in the password
dialogue box to get to the Problem Editor. If you have set up a password,
type it in and click OK.

The Problem
Password
Editor is
password Enter Password:
protected.
OK

For extra Change

security, the
characters you
Cancel
enter are
displayed as

*******

3. Create a new problem by selecting New Problem from the File menu.

Select New Problem

from the File Menu, or
press F3.

Though this step isn’t necessary when first opening the Problem Editor,
get into the habit of doing so to avoid overwriting an active problem.
This will be explained later in the tutorial.
4. In the Problem Editor’s Fault Conditions menu, find and select Cylinder
1 Hi Side by using the scroll bar at the side.

Select the desired Fault Condition Navigate through the list by dragging
by double clicking it. the scroll bar with the mouse.

Fault Conditions
CAT Data Link
Check Engine Lamp
Coolant Temperature
Cylinder 1 Hi Side
Cylinder 2 Hi Side
Cylinder 3 Hi Side Short to Low Side
Cylinder 4 Hi Side
Cylinder 5 Low Side
EMS Coolant Temperature Lamp

The Caterpillar Engine Simulator 3-9

 System operation & quick tutorial
Setting up a problem

The Fault Conditions menu is a list of electronic engine signals in the

application you are using.
5. Stage a short-to-ground fault in the high side wire harness going to the
injector solenoid.
Click on Short to Ground in the Harness Faults box to create the short-
to-ground condition. When you do this, you should hear a click when
the relay opens to physically short the wire on the component panel.

Grayed options are not available Make selections by clicking

to the selected fault condition. on the fault title’s button.

Fault Options: Air Inlet Restriction Lamp

Defaults
Fault Times... None

Sensor Faults Harness Faults

Normal Normal

Open

Override Percent

Sensor Faults can be assigned to sensors. Faults include Sensor Short-

to-Ground, Sensor Short to +Battery, Sensor Open, and Sensor Over-
ride. If the sensor fault does not fall into one of the above categories, the
Other button will be enabled. The sensor default is Normal, or no fault.
Sensor faults are introduced by the PC driving a sensor signal higher or
lower than normal.
Harness faults can be assigned to any wiring component. Faults include
Wire Short to Ground and Wire Open. The wiring default is Normal, or
no fault. Hardware faults that are simulated on the component panel
originate at the relays, physically shorting or opening the relay contacts.
Override Percent can be applied to signals. For instance, you can over-
ride the Engine Temperature reading by 120 percent, making the engine
appear hotter than it actually is.

The Caterpillar Engine Simulator 3-10

 System operation & quick tutorial
Setting up a problem

If fault options are gray, they cannot be applied to the component or sig-
nal that was selected. For example, in the illustration above, Short to
Ground Sensor Fault is one fault that cannot be assigned to a Cylinder 1
Hi-Side wire. If you click on a grayed option, nothing happens.
Because the fault condition has been activated by selecting Short to
Ground, the Fault Times option becomes active. This option allows
you to delay the fault or cause it to occur intermittently. For this tutorial,
keep the fault from occurring until the problem has been active for
one minute.
Click the Default button to return all fault conditions to normal.
6. Click on the Fault Times button. Use the scroll bar in the Delay Time
area to set the time to 1 minute. Click OK.
Intermittent Time Fault Times

settings allow Intermittent Times

OK
control of time and
0:00 Minimum (Min:Sec)
duration of faults. Defaults
0:00 Maximum (Min:Sec)
Cancel
0:00 Duration (Min:Sec)
Set the Delay Time
Delay Time Override Ramp Time
by moving the scroll
bar with the mouse. 0:00 (Min:Sec)
0:00 Duration (Min:Sec)

The Defaults button

7. Assign a description to the fault.

8. Open the Edit menu and click on Problem Description.
Problem Description
Enter Description
OK

Cancel

The Caterpillar Engine Simulator 3-11

 System operation & quick tutorial
Setting up a problem

Enter a short description in the dialogue box. The description is for your
own reference when compiling lessons or viewing faults. Click OK to
enter the description.
9. If you choose, you can reveal fault symptoms to the student.
Select Problem Symptom from the Edit menu. Enter a symptom for the
fault. Click OK.

Problem Symptoms
Enter Symptoms
OK

Symptoms Cancel
can be
viewed by Engine start missing after one
students. minute of operation

10. Select Faults from the View menu to see the problem in its entirety.
Electronic Training Aid (untitled)
File View Edit Window Help

Description: Return to Editor

Fault Condition State Override Value

Legend
S = Short Gnd
O = Open
V = Override
D = Delay
I = Intermittent

Use this key to identify abbreviations.

The Caterpillar Engine Simulator 3-12

 System operation & quick tutorial
Saving problems

The faults and override values assigned to a problem are listed with their
fault condition. A key at the side of the screen explain each fault abbre-
viation.
Click on Return to Editor to get out of the View Faults screen.

Saving problems
1. Open the File menu and choose Save Problem.
Typea filename in the Save Problem As Dialogue box. All file names
must be eight characters or less.

Save Problem As
Filename: OK
agigrver.prb
Cancel
agigrver.prb
cltemov.prb
datm3.prb
dcyl2.prb
dst3.prb
dthrot2.prb
hatm0.prb
hcool0.prb
hcool1.prb

2. Click OK.

The problem is now saved. However, even though it has been saved, the
problem is still active in the computer’s memory. Be sure to create a new
problem before selecting Fault Conditions and Fault Options for your
next problem.

Generating more problems

1. Create several practice problems on your own using the previous
instructions.
2. To create a new problem, open the File menu and choose New Problem,
or press F3. This returns the Problem Editor to its default setting where
all conditions are normal and functioning properly.
3. Repeat the steps just covered for creating and saving problems.

The Caterpillar Engine Simulator 3-13

 System operation & quick tutorial
Compiling problems into a lesson

4. If you wish to make changes to a problem you made earlier, reopen it by

selecting Open Problem in the File menu and selecting the desired file.
Save the problem when you have completed the changes.
5. If you wish to create a new problem based on settings in an old problem,
open the old problem by selecting Open Problem in the File menu and
selecting the desired file. Make the desired changes that will become the
new problem.

Select Save Problem As... from the File menu. Type a name for the new
problem under “Filename:” in the Save Problem As dialogue box. Click
OK. Both the old and new problems are now saved.
After creating and saving several problems, save them as a lesson for the
student mode.

Compiling problems into a lesson

After creating fault conditions and saving them as problems, compile them
into a lesson for student training. Students can access the problems only
while working on lessons. You may want to create lessons around certain
themes, such as electronic fuel system failures, or based on the student’s
knowledge level. The following instructions will take you through the steps
for viewing all problems and selecting only those needed for a training les-
son.

1. Select Lesson Editor from the Window menu.

The Lesson Editor reveals all the problems that have been created
and saved for the current application.
2. Select New Lesson from the File menu.

The Caterpillar Engine Simulator 3-14

 System operation & quick tutorial
Saving the lesson

3. Select a problem from the “Problems” box and click Add >>.
Electronic Training Aid (untitled)
File View Edit Window Help

Select the Problems you wish to add to this Lesson:

Problems: Lesson Consists of:

Add

Delete

A copy of the problem is moved into the “Lesson Consists of:” box.
Choose several additional problems that you want in the lesson and click
Add >>.
4. If you wish to compile a lesson in a particular order, select and add
problems individually in the desired order.
5. To remove a problem from the lesson, choose the problem from the
“Lesson Consists of:” box and click << Delete.
6. Select Lesson Notes from the Edit menu. Type in a short description of
the lesson in the dialogue box.
This description will appear above the lesson selection menu in the
Open Lesson dialogue box. You may assign notes before or after saving
the lesson.

Saving the lesson

1. While in the Lesson Editor, choose Save Lesson from the File menu.

The Caterpillar Engine Simulator 3-15

 System operation & quick tutorial
Editing the lesson

2. In the Save Lesson As dialogue box type a file name.

Save Lesson As
Filename:
OK
*.les

Cancel

advanced.les
basic.les
ecap.les
flashcod.les
inject.les
sensors.les
t1.les
t2.les
test1.les

The problem is now saved. Again, although the lesson has been saved, it
is still in the computer’s memory. Be sure to select New Lesson from the
File menu before compiling problems into a different lesson.

Editing the lesson

For the purpose of this tutorial, re-open the lesson you just saved and remove
one of the problems.

1. Turn the ignition to OFF. Let the engine RPMs fall to zero RPMs and
switch the power to ON.
2. In the Lesson Editor, select Open Lesson from the file menu.
3. Use the scroll bar on the lesson selection menu to view lessons. Click on
it once.
4. Select Lesson Notes from the Edit menu to view the lesson description
you entered earlier. Click OK.
5. Click on one of the problems in the Lesson Consists of menu.
6. Click the <<Delete button.
7. Change lesson notes if desired.
8. Select Save Lesson from the File menu.
If you wish to save this variation of the original lesson under a new
name, choose Save As from the File menu, and assign a new file name.

The Caterpillar Engine Simulator 3-16

 System operation & quick tutorial
Preparing the student exercise

Preparing the student exercise

Note that all lesson and problem controls are disabled while the engine
is running. In other words, you must turn off the engine to load a lesson
or move from problem to problem.
1. Select Simulator from the Window menu to return to the ETA’s
Simulator screen.
2. Select Open Lesson from the File menu.
3. Select a lesson and click OK.
Open Lesson
Filename:
OK
basic.les
Cancel
Description:
Beginner trouble-shooting

advanced.les
basic.les
ecap.les
flashcod.les
inject.les
sensors.les

The lesson you just created is now in the computer’s memory, and the
first problem is active. The lesson name and the problem number are
displayed at the bottom of the Simulator screen.
4. Select Next Problem or Previous Problem from the Faults menu to move
from question to question.

The Caterpillar Engine Simulator 3-17

 System operation & quick tutorial
Changing your password

5. Press Start on the ETA’s Simulator screen to start the engine.

6. Select View Symptoms from the Faults menu to see any symptoms
that may have been included.
7. After the student completes the lesson, choose Close Lesson to remove
the Lesson from the computer’s memory.
Choose Clear Faults from the Faults menu if you want to pause during
the lesson without closing it. This selection resets the lesson to problem
zero, or faultless operating condition.

Changing your password

Password protection for the Problem and Lesson Editor is optional. It can be
changed by the instructor at any time. The ETA software is shipped without a
password.

1. In the ETA’s Simulator screen, choose Problem Editor or Lesson Editor

from the Window menu.
2. Choose Change from the Password dialogue box.

The Caterpillar Engine Simulator 3-18

 System operation & quick tutorial
Shutting down the ETA

3. In the Password Change dialogue box, enter the old password (click OK
if you are creating a password). Choose OK.

Password
Enter Password: OK

Change

Cancel

*******

4. Enter the new password. After the dialogue box prompts you, reenter
the new password for verification.
5. Choose OK.
6. To run the Electronic Training Aid without password protection, press
Enter (Return Key) instead of typing in a new password as instructed in
Step 4.

If the password is forgotten or lost, call Techcom, Inc., Simulator

Technical Support at (317) 898-2721.

Shutting down the ETA

1. Open the File menu and select Exit. You should be able to hear the
Engine Component Panel shut down.
2. Turn off the Main Power switch on the component panel.
3. If you wish to exit Windows 3.1, choose Exit from the File menu. To
exit Windows 95, click the Start button and click Shut Down.
Note: Always exit Windows before turning off the computer.
4. Turn off the power to the computer.

The Caterpillar Engine Simulator 3-19

 4 Training on the Simulator

The Engine Component Panel 4-3

The on-screen functions 4-5

Connecting ECAP 4-6

Connecting the Timing Calibration Jumper 4-7

The Caterpillar Engine Simulator 4-1

 4 Training on the Simulator

Before a student begins a lesson, some preparation must be made. Find out if
the student has any computer experience. If not, briefly explain the computer
and its components.

Explain that many Simulator functions, like adjusting the throttle and load,
can be done from the Engine Component Panel or the computer. However,
navigating through lessons and the on-line reference manual is only possible
on the computer. Note that load has no effect on the Simulator unless the
engine is in gear, a function that can only be achieved from the Application’s
ETA screen. Additionally, certain gauges, meters, and warning lamps can
only be found on the Application’s ETA screen. The on-screen radio button
must be selected to operate the load, throttle, and four toggle switches on the
PC.

Give the student a guided tour of the Engine Component Panel. Point out the
sensors, solenoids, and other equipment on the Simulator that will be active
in the current application (refer to the Application Guide). Also point out the
Service Connector for Electronic Service Tool communication and explain
what functions the toggle switches and push buttons perform. Explain that
problem troubleshooting should be performed on the Simulator as it would
be in the field. Diagnostic equipment can be connected to the Simulator
before or after opening a lesson.

Allow the student to observe while you turn on the Main Power switches and
load the ETA program. Show the student how to use the online reference
material. Navigate through all the information screens before returning to the
Application Introduction screen.

The Caterpillar Engine Simulator 4-2

 Training on the Simulator
The Engine Component Panel

The Engine Component Panel

The Engine Component Panel is the link between the student and the ETA
program. This unit allows the student to connect diagnostic tools to the same
type wires and contacts and connectors found on Caterpillar engines and
their applications. Before starting the program, familiarize yourself and your
student with the hardware.

A B C D

E
F

G H
I

A Sensor bank
The sensor bank consists of two speed/timing sensors, three temperature sen-
sors, and seven pressure sensors. These are functioning sensors, though
some may be inactive depending on the application. Refer to your Applica-
tion Guide for specific information.

The Caterpillar Engine Simulator 4-3

 Training on the Simulator
The Engine Component Panel

B Injector lamps
Directly above the sensor bank are the injector lamps. They represent firing
injectors. If the piston’s injector is not firing because of a fault that has been
programmed into a problem, it will be indicated by the injector lamps. The
Lamps switch on the back of the panel disables the injector lamps.

C Speaker
The speaker emits a simulated engine sound. A missing cylinder can be
detected from the sound coming from the speaker. The volume control for
the speaker is located on the back of the panel.

D Solenoid connectors
The solenoid connectors are for 3.5 Amp solenoids. Their use is application
specific.

E-G ECM and harness

The ECM (E), the ECM harness (F), and the ECM harness connector ports
(G) are all application specific. Correct installation (and any necessary
programming) of the ECM is very important. The computer communicates
directly with the ECM, just as an engine does in a real life application. See
your Application Guide for correct part numbers and the proper harness
connection port.

H Throttle connector
The throttle connector may be disconnected and connected to an actual
throttle control.

I Instrument panel
The instrument panel consists of a tachometer, a warning lamp, throttle and
load control potentiometers, an ignition switch and crank push-button, and
four application specific toggle switches. Again, a key to application-specific
components can be found in your Application Guide.

J Service Ports
The service ports for various types of diagnostics tools are located on the
front panel. Your Application Guide will tell you which ports are active
for the application. The 9-pin service connector port is provided for the
Electronic Service Tool) hookup or other datalink uses.

The Caterpillar Engine Simulator 4-4

 Training on the Simulator
The Engine Component Panel

The Engine Component Panel

The Engine Component Panel is the link between the student and the ETA
program. This unit allows the student to connect diagnostic tools to the same
type wires and contacts and connectors found on Caterpillar engines and
their applications. Before starting the program, familiarize yourself and your
student with the hardware.

A B C D

E
F

G H
I

A Sensor bank
The sensor bank consists of two speed/timing sensors, three temperature sen-
sors, and seven pressure sensors. These are functioning sensors, though
some may be inactive depending on the application. Refer to your Applica-
tion Guide for specific information.

The Caterpillar Engine Simulator 4-3

 Training on the Simulator
The Engine Component Panel

B Injector lamps
Directly above the sensor bank are the injector lamps. They represent firing
injectors. If the piston’s injector is not firing because of a fault that has been
programmed into a problem, it will be indicated by the injector lamps. The
Lamps switch on the back of the panel disables the injector lamps.

C Speaker
The speaker emits a simulated engine sound. A missing cylinder can be
detected from the sound coming from the speaker. The volume control for
the speaker is located on the back of the panel.

D Solenoid connectors
The solenoid connectors are for 3.5 Amp solenoids. Their use is application
specific.

E-G ECM and harness

The ECM (E), the ECM harness (F), and the ECM harness connector ports
(G) are all application specific. Correct installation (and any necessary
programming) of the ECM is very important. The computer communicates
directly with the ECM, just as an engine does in a real life application. See
your Application Guide for correct part numbers and the proper harness
connection port.

H Throttle connector
The throttle connector may be disconnected and connected to an actual
throttle control.

I Instrument panel
The instrument panel consists of a tachometer, a warning lamp, throttle and
load control potentiometers, an ignition switch and crank push-button, and
four application specific toggle switches. Again, a key to application-specific
components can be found in your Application Guide.

J Service Ports
The service ports for various types of diagnostics tools are located on the
front panel. Your Application Guide will tell you which ports are active
for the application. The 9-pin service connector port is provided for the
Electronic Service Tool) hookup or other datalink uses.

The Caterpillar Engine Simulator 4-4

 Training on the Simulator
The Engine Component Panel

The Engine Component Panel

The Engine Component Panel is the link between the student and the ETA
program. This unit allows the student to connect diagnostic tools to the same
type wires and contacts and connectors found on Caterpillar engines and
their applications. Before starting the program, familiarize yourself and your
student with the hardware.

A B C D

E
F

G H
I

A Sensor bank
The sensor bank consists of two speed/timing sensors, three temperature sen-
sors, and seven pressure sensors. These are functioning sensors, though
some may be inactive depending on the application. Refer to your Applica-
tion Guide for specific information.

The Caterpillar Engine Simulator 4-3

 Training on the Simulator
The Engine Component Panel

B Injector lamps
Directly above the sensor bank are the injector lamps. They represent firing
injectors. If the piston’s injector is not firing because of a fault that has been
programmed into a problem, it will be indicated by the injector lamps. The
Lamps switch on the back of the panel disables the injector lamps.

C Speaker
The speaker emits a simulated engine sound. A missing cylinder can be
detected from the sound coming from the speaker. The volume control for
the speaker is located on the back of the panel.

D Solenoid connectors
The solenoid connectors are for 3.5 Amp solenoids. Their use is application
specific.

E-G ECM and harness

The ECM (E), the ECM harness (F), and the ECM harness connector ports
(G) are all application specific. Correct installation (and any necessary
programming) of the ECM is very important. The computer communicates
directly with the ECM, just as an engine does in a real life application. See
your Application Guide for correct part numbers and the proper harness
connection port.

H Throttle connector
The throttle connector may be disconnected and connected to an actual
throttle control.

I Instrument panel
The instrument panel consists of a tachometer, a warning lamp, throttle and
load control potentiometers, an ignition switch and crank push-button, and
four application specific toggle switches. Again, a key to application-specific
components can be found in your Application Guide.

J Service Ports
The service ports for various types of diagnostics tools are located on the
front panel. Your Application Guide will tell you which ports are active
for the application. The 9-pin service connector port is provided for the
Electronic Service Tool) hookup or other datalink uses.

The Caterpillar Engine Simulator 4-4

 Training on the Simulator
The on-screen functions

The on-screen functions

Shifting gears
Gear shifting is available from the ETA’s Simulator screen with either
On-Screen or Physical Panel selected. There are no gear selection controls
on the Engine Component Panel.

1. In the Desired Gear box, click the Up button to shift to a higher drive
gear.
2. Click the Down button to downshift.

Change gears by
clicking the Up/Down
buttons with your
mouse

Setting engine speed and load

These settings may be performed from the Engine Component Panel or from
the ETA’s Simulator screen. (Refer to your Application Guide for location of
speed and load controls on the component panel.)

1. On the screen, move the mouse over the Throttle or Load controller.
2. Hold down the mouse button.
3. Move the slide handle up to increase the setting.
4. Slide the handle down to decrease the setting.
Adjust the throttle and
load control by moving
the slide handle with
the mouse...

...or click the Up/

Down Arrow buttons
to adjust the controls
in increments.

These settings may also be adjusted by clicking on the Up/Down Arrow

buttons on either side of the slide handle.

The Caterpillar Engine Simulator 4-5

 Training on the Simulator
Connecting Electronic Service Tool

Using toggle switches

The ETA’s Simulator screen has functioning toggle switches. Their number
and purpose depends on the loaded application.

Click this button to

move the toggle
to the UP
position.

Click this button

to move the
toggle to the
DOWN position.

1. To change the position of a screen toggle switch to the up position, click

the toggle’s Up button.
2. To change the position of a screen toggle switch to the down position,
click the toggle’s Down button.

Connecting Electronic Service Tool

Use the 9-pin Service Connector and Communication Adapter tool to link
your Electronic Service Tool to the ECM.

Connector port
for Electronic
Service Tool.

Set up the Electronic Service Tool and Communication Adapter tool accord-
ing to the instruction in the application’s Electronic Troubleshooting manual.

The Caterpillar Engine Simulator 4-6

 Training on the Simulator
Connecting the Timing Calibration Jumper

Connecting the Timing Calibration Jumper

When performing diagnostics on an engine’s timing calibration, use the fol-
lowing procedure for connecting the Timing Calibration Jumper to the con-
nector on the ECM wiring harness.

1. Install the Timing Calibration Probe into the threaded port on the
Engine Component Panel. Use the same procedures that would be used
on a real engine. Plug the RCA jack into the port directly beside the
threaded probe port. This step is optional. However, it is a good way to
train students to install the Timing Calibration Probe.
2. Plug the Timing Calibration Jumper’s 1/4" stereo jack into the port
labeled Timing Calibration Jumper.

Install the
Timing
Calibration
Probe into the
threaded port.

RCA Plug 1/4" Stereo Jack

3. Connect the other end of the jumper to the connector on the ECM wiring
harness. Your Application Guide will help you locate
this connector.

The Caterpillar Engine Simulator 4-7

A Appendix

Setting up user-supplied computers

On systems purchased without the computer, it is the customer’s
responsibility to obtain a computer that matches the requirements listed in
“System requirements.” It is very important that you match the architecture,
or structure, of your computer so existing and future interface cards can be
installed. Without the necessary Industry Standard Architecture (ISA)
slots, your Caterpillar Engine Simulator may have limited use or it may
not function at all.

Also, be aware that different computer manufacturers may use a different

communications system. If this is so, your computer’s peripherals and the
ETA expansion cards may have conflicting addresses.

Before installing the ETA interface cards in your computer, make sure
your Simulator package has the following parts:

• 1 PXB721M interface card (CARD 1)

• 1 PXB72lF interface card (CARD 2)
1 ADM8-10 card, installed on PXB72lF
2 DM8-10 cards, installed on PXB72lF
• 1 CMAX-20 interface card, holder & clamp installed (CARD 3)
• 2 card-mounting brackets for cards 1 and 2
• 1 clamp
• 3 ribbon cable protectors
• 7 ribbon cables (J6 through J13)
• 1 CATETA93O3 connector board w/ connectors
• 1 engine component panel to ETA connector box case

If you are missing any of these parts, contact Techcom, Inc. Simulator
Technical Support at (317) 898-2721 immediately. Consult your computer
manufacturer’s owner’s manual for instructions on installing expansion cards.

The Caterpillar Engine Simulator A-1

 Appendix A
Setting up user-supplied computers

WARNING
Turn off and disconnect your computer
and all peripherals before working
inside the computer. Electric shock can
cause personal injury and damage to
equipment.

Refer to the illustration below for placement of ETA interface cards and
cable hookup.

1. Install card PXB721M in slot 2.

2. Install card PXB721F in slot 3.
3. Install card CMAX-20 in slot 4.

The Caterpillar Engine Simulator A-2

B Appendix

Programming the ECM

The ETA program cannot communicate with an ECM unless the ECM has
been programmed for the new application. To program an ECM you must
have the following tools:

• 1 Electronic Service Tool

• 1 Communication adapter tool
• 1 Connector cable (Electronic Service Tool to communication adapter.)
• 1 Nine-pin connector cable (Communication adapter to Engine
Component Panel)

The following procedures for programming the ECM cover only the steps
associated with the Caterpillar Engine Simulator. Refer to the application’s
Electronic Troubleshooting Manual, “Programming EUI Parameters,” for
specific programming instruction. The engine prefix and machine serial
numbers are found in your Application Guide.

Warning: Do not use any other serial numbers. The serial numbers given in
the application guide have been set up in the Caterpillar system as training
aids. If a different number is used, you may key on an actual machine when
you attempt to get factory passwords in the Caterpillar Warranty system.
This will cause difficulty in the system.

1. Mount and connect the ECM. For help with this, see “Setting up your
system”. Remember that if your application uses a 16-cylinder applica-
tion ECM, the personality module must be installed before mounting.

The Caterpillar Engine Simulator B-1

 Appendix B
Programming the ECM

2. Make sure the Ignition Switch on the front of the Engine Component
Panel and the Main Power switch on the back of the panel are in the OFF
position. Connect power to the Engine Component Panel and turn the
Main Power switch ON.

Main Power switch

Main power hookup

3. Connect a Communication Adapter Tool to the 9-pin Service

Connector Port on the front of the Engine Component Panel.

Connector port for

Electronic
Service Tool.

4. Follow the procedures listed in the application’s Electronic Trouble-

shooting Manual under “Programming EUI Parameters.”
5. When entering Read/Change parameters, enter the 8-character engine
and machine serial numbers. These codes are found in your Application
Guide, “EUI programming information.”

Note: Do not use any other serial numbers. The serial numbers given in the
application guide have been set up in the Caterpillar system as training
aids. If a different number is used you may key on an actual machine
when you attempt to get factory passwords in the Caterpillar Warranty
system, causing difficulty in the system.
6. After programming is complete, remove the Communication Adapter
tool from the Service Connector Port, or leave it in for Simulator trou-
bleshooting.

The Caterpillar Engine Simulator B-2

C Appendix

Menu maps

Choose Lesson
Lesson: OK
*.les
Cancel
Choose Lesson:
advanced.les
basic.les
ecap.les
flashcod.les
inject.les
sensors.les
t1.les
t2.les

The Caterpillar Engine Simulator C-1

 Appendix C
Menu maps

The Caterpillar Engine Simulator C-2

 Appendix C
Menu maps

The Caterpillar Engine Simulator C-3

 Appendix C
Menu maps

Set Preferences
Units Sound

English On
Metric Off

ECM Ambient Conditions

ECM Part Number

118-7361
Available in a
Prompt future release

Always use EPTC II

Always use ARC

OK Restore Defaults

The Caterpillar Engine Simulator C-4

 Appendix C
Menu maps

Open Problem
Filename:
OK
agigrver.prb
Cancel
Description:
Actual gear indicator ground verify
open...
agigver.prb
cltemov.prb
datm3.prb
dcyl2.prb
dst3.prb
dthrot2.prb

Save Problem As
Filename: OK
agigrver.prb
Cancel
agigrver.prb
cltemov.prb
datm3.prb
dcyl2.prb
dst3.prb
dthrot2.prb
hatm0.prb
hcool0.prb
hcool1.prb

The Caterpillar Engine Simulator C-5

 Appendix C
Menu maps

Problem Description
Enter Description
OK

Cancel

Problem Symptoms
Enter Symptoms
OK

Cancel

The Caterpillar Engine Simulator C-6

 Appendix C
Menu maps

Open Lesson
Filename:
OK
basic.les
Cancel
Description:
Beginner trouble-shooting

advanced.les
basic.les
ecap.les
flashcod.les
inject.les
sensors.les

Save Lesson As
Filename:
OK
*.les

Cancel

advanced.les
basic.les
ecap.les
flashcod.les
inject.les
sensors.les
t1.les
t2.les
test1.les

The Caterpillar Engine Simulator C-7

 Appendix C
Menu maps

Lesson Notes

Enter Notes OK

Cancel

The Caterpillar Engine Simulator C-8

 Appendix C
Menu maps

Electronic Training Aid (untitled)

File View Edit Window Help

Description: Return to Editor

Fault Condition State Override Value

Legend
S = Short Gnd
O = Open
V = Override
D = Delay
I = Intermittent

Electronic Training Aid (Untitled)

File View Edit Window Help

Lesson Notes: Return to Editor

Drive:\Path\File

The Caterpillar Engine Simulator C-9

3176B
Application Guide

3176B Marine Engine

The 3176B Marine application is a software training module for the
Caterpillar Engine Simulator’s Electronic Training Aid program. Use this
module to train on the 3176 engine’s EUI system.

The following pages include specifications for Simulator setup and

general information.

Note: A Phase II hardware upgrade is necessary to run this application.

The Caterpillar Engine Simulator 3176B-1

 3176B Application
EUI System Specs
EUI System Specs
ECM 117-8351

ECM Harness 126-7437

ECM Harness Port Connect to Ports A & B

EUI Parameters Serial Number: 9WK00001

Personality Module 125-2178

Engine Component Panel Volt- Set to local voltage

age Selector (115Vac OR 220Vac)

ECM Power Selector 24Vdc

Required Connector Cables J1, J2, J3, RS232

Rubber Mounts 8T9655 (qty. 8)

Spacer 6I1418 (qty. 4)

Hardware Upgrade Modified 9303 connector board

9301 circuit board

3176B Marine PC Software LERV5164 (supported by ETA

software version 1.31 and higher)

Dashboard for the 3176B Marine

The Caterpillar Engine Simulator 3176B-2

 3176B Application
Engine Panel Sensor Locations
Engine Panel Sensor Locations

Secondary Speed/Timing Speed/Timing

Coolant Intake Air

Temperature Fuel
Temperature
Atmospheric
Turbo Outlet
Pressure
Pressure
Oil Pressure

Fuel Pressure Non-Panel

Sensors
Coolant
Transmission Oil Level
Pressure
Transmission Oil
Temperature

Instrument Panel
Remote Trolling
Shutdown Mode Throttle Load Crank

VID
Slow
Lamp Vessel Display Ignition
Scroll

The Caterpillar Engine Simulator 3176B-3

 3176B Application
Engine Panel Sensor Locations

Electronic Control System Diagram

Electronic Unit Injectors ECM Battery

Trip Data Recorder Switch

TDC Service Probe Access
Engine Harness Engine Shutdown Switch
Speed/Timing Sensor
Trolling Mode Switch
Back-Up Speed Timing Sensor Synchronization Switch
Slow Vessel Mode Swithc
Coolant Temperature Sensor
Primary Trhottle
Oil Pressure Sensor Transmission Oil Temp
Transmission Oil Press
Inlet Manifold Air Temp Sensor
CAT EMS
Inlet Manifold Press Sensor
Data Link
Atmospheric Press Sensor Warning System Interface
Low Oil Pressure
High Oil Temp
Low Coolant Level
Transmission Temp/Press
Service Tool Maintenance Indicator
Diagnostic Lamp
Electronic Control Fuel Temp Coolant Level
Analyzer Programmer Sensor Switch

ECM Harness Port Connections

Timing Calibration Connector

Connector B Connector A

The Caterpillar Engine Simulator 3176B-4

On-Highway Truck
Application Guide

On-Highway Truck

The On-Highway Truck Application is a software training module for the

Caterpillar Engine Simulator’s Electronic Training Aid program. Use of this
module is recommended to train on the 3176B, C-10, C-12 or 3406E On-
Highway Truck Engine’s Electronic Control System.

The following pages include specifications using 3406E components for the
Caterpillar Engine Simulator setup and general information.

NOTE: A Phase II hardware upgrade is necessary to run this application.

Examine your Training Aid Engine Simulator Panel to ensure it is upgraded
to Phase II. A version 5 HC11 microprocessor chip is recommended, but not
required, to ensure the Timing Calibration can be performed as well.

The Caterpillar Engine Simulator 3406E-1

 3406E Application
Application Specifications
Application Specifications
ECM Part No. 117-8351
ECM Mounting
Grommet Part No. (8) 8T9655
Bushing Part No. (4) 6I1418
Washer Part No. (8) 9N0869
Application/ECM Harness Part No. 141-2645
Connects ECM (J1 & J2) to
Training Aid Ports (A & B)
Personality Module (Flash File) Part No. or... 120-4050 Jan95 or...
Personality Module Part No. 120-4052
ECM Power Selector 12 VDC
Engine Panel Voltage Selector Set to local voltage
(115 VAC or 220 VAC)
Customer Specified Parameter - Vehicle ID # S0000001D
Customer Specified Parameter - Eng Serial # 5EK00001
Recommended Electronic Service Tool Electronic Technician (ET)
Alternate Electronic Service Tool Electronic Control Analyzer
(limited functionality) & Programmer (ECAP)
Required Data Link Harness 7X-1412 (ATA)
Required PC to Panel Connector Cables J1, J2, J3, RS-232
On-Highway Truck Engine Install Software LERV7400 (version 2.0)

The Caterpillar Engine Simulator 3406E-2

 3406E Application
Application Specifications
Engine Panel Sensor Locations

Speed/Timing
Sensor
Inlet Manifold
Coolant
Air Temperature
Temperature
Sensor
Sensor
Fuel
Boost Temperature
Pressure Sensor
Sensor
Atmospheric
Pressure
Sensor

Oil
Pressure
Sensor

Instrument Panel
Check Engine Lamp Throttle Load
Tachometer Cruise ON/OFF

Brake Clutch Set/Resume Ignition Crank

NOTE: Four switch panels are available for this application in the Simulator PC
Screen “View” menu, however, the physical panel is only equivalent to the “Brake
Clutch Cruise Panel” functions. Refer to “Using the On-Highway Truck Engine

The Caterpillar Engine Simulator 3406E-3

 3406E Application
Application Specifications
Application Training Aid” for information regarding “Cab PTO, Remote PTO &
Engine Brake/Retarder” switch panel screens.

ECM Harness Port Connections

Timing
Connector B Connector A Calibration
Connector

Electronic Control System Diagram

-
24V
+ Vehicle
Electronic Unit
Injectors
Engine Control Main
15 Amp Breaker Power
Relay
ECM
TDC Service Probe Access ATA Data Link Keyswitch
Service Tool
Accelerator Pedal
Oil Pressure Sensor (Filtered) Throttle Position Sensor

Ground Bolt
Vehicle Speed Sensor
Boost Pressure Sensor
Engine Harness
Speedometer Tachometer
Speed Timing Sensor
Vehicle Harness Warning and CheckEngine Lamps
Coolant Temperature Sensor
Retarder Solenoid Switches AC Pressure Switch
Inlet Manifold Air
Temperature Sensor Cruise ON/OFF &
Coolant Level Sensor SET/RESUME Swirches

Fuel Temperature Sensor

Service Brake Switch
Cooling Fan and
Atmospheric Pressure
Sensor Clutch Switch
Engine Brake Relay

The Caterpillar Engine Simulator 3406E-4

 3406E Application
Application Specifications
Model Views.
Inlet Manifold Air
Fuel Temperature Temperature Sensor
Sensor Injector Connector
J5/P5

Boost Pressure
Sensor
Engine
Speed/Timing
Sensor ECM Connector
J2/P2

Electronic Control
Module

ECM Connector
J1/P1

Timing Calibration
Port
Atmospheric Pressure
Sensor

Left Side View

Coolant

Oil Pressure Temperature

Sensor Sensor

Right Side View

The Caterpillar Engine Simulator 3406E-5

 3406E Application
Application Specifications

Engine
Speed/Timing
Sensor

Coolant
Temperature
Sensor

Front View

The Caterpillar Engine Simulator 3406E-6

 3406E Application
Using the On-Highway Truck Engine Application Training Aid
Using the On-Highway Truck Engine Application Training
Aid
The On-Highway Truck Training Aid is intended to be used with the Caterpillar
Electronic Service Tool is required for full functionality.

Simulator Screen for the On-Highway Application

Application Specific Notes:

1. Four switch panels are available under the “View” menu; however, only the
first panel, “Brake Clutch Cruise Panel,” matches the physical panel for
switch functionality.
2. In order to use the Cab PTO or Remote PTO panels, you must change the
PTO “Configuration” screen on the Electronic Service Tool to Remote
Switches or Cab Switches. Refer to “Optional Simulator Screen Display” on
page -10.

The Caterpillar Engine Simulator 3406E-7

 3406E Application
Using the On-Highway Truck Engine Application Training Aid
Start/Stop Control and Throttle Simulation

Two buttons will allow the student to select between On-screen Control and
Physical Panel Control.

The simulation control panel has slider bars to control both the engine load
and throttle position. A standard throttle system is simulated that duplicates
the truck throttle system.

An ignition key start switch is simulated. Pressing the buttons next to the
“OFF”, “RUN” and “START” text boxes on the screen will place the switch
between the three positions and the engine start sequence begins. In
addition, when the start button is released the key switch will return to the
“RUN” position. Once “START” has been selected, the key switch must be
placed in the “OFF” position before selecting “START” again to restart the
“engine”.

Throttle

When the throttle position slider bar (or potentiometer on physical panel) are
at low position, the duty cycle output is approximately 10%. When the
throttle position slider (or potentiometer on physical panel) are at high
position, the duty cycle output is approximately 92%.

Tachometer

Needle moves clockwise as engine speed increases.

Gauge displays 0-3500 rpm. Normal operating range is 0-2100 rpm.

Coolant Temperature Gauge

Needle moves clockwise as coolant temperature increases. Needle moves

between 150F and 250F.

Oil Pressure Gauge

Needle moves clockwise as oil pressure increases. Needle moves between

5 psi and 100 psi.

Check Engine Lamp & Warning Lamp

The check engine lamp (amber) and Warning Lamp (red) are controlled by
an output from the ECM. They are visible at start-up and when a diagnostic
is active. At any other time the lamp is not visible.

The Caterpillar Engine Simulator 3406E-8

 3406E Application
Using the On-Highway Truck Engine Application Training Aid
Retarder Level Lamp

The desired retarder operation is controlled by both the Retarder ON/OFF switch
position and the Retarder Level (HI/MED/LO) switch position. The actual retarder
operation is controlled by the ECM, based on the switch inputs as well as other
functions. If switch inputs are correct and the ECM determines that conditions are
correct, then the retarder is “ON” and active and causes the engine rpm (tachometer)
and vehicle speed (speedometer) to decrease.

Fan

The fan is controlled by an output from the ECM. The lamp graphic turns “ON” and
“OFF” under certain conditions such as when in PTO mode. The fan graphic rotates
to simulate that the fan is ON.

Transmission

The transmission for the On-Highway Truck is a manual transmission. The gear
range is from 1st to 10th with neutral and reverse. There cannot be a shift from
forward to reverse with vehicle speed being greater than 3 mph. A reference table of
gear ratios is shown below.

Gear Ratio Gear Ratio Gear Ratio

Reverse 375:1 3rd 220:1 7th 65:1

Neutral 1-3500:0 4th 150:1 8th 45:1

1st 375:1 5th 115:1 9th 35:1

2nd 310:1 6th 90:1 10th 25:1

The Caterpillar Engine Simulator 3406E-9

 3406E Application
Optional Simulator Screen Display
Optional Simulator Screen Display
NOTE: Additional switches may be accessed by a menu option. The screens provide
optional choices and functions for the toggle switches.

Switch Panels

Set
I I I

0 0 0
Brake Resume
Clutch
Cruise Cruise

Panel 1-Brake/Clutch Cruise Panel

Brake Switch

The brake switch is located on ALL simulator screen panels and the physical panel.
The switch is momentary toggle, normally closed. When the switch is released (down
position), the brake is inactive. When the switch is depressed (up position), the brake
is activated.

Clutch Switch

The clutch switch is located on the physical panel, and simulator screen switch panels
1, 3, 4 (Brake/Clutch Cruise, Cab PTO, & Remote PTO Panels). The switch is momentary
toggle, normally closed. When the switch is released (down position), the clutch is
inactive. When the switch is depressed (up position), the clutch is activated.

NOTE: When shifting gears, the clutch is automatically disengaged & engaged by
the simulator.

The Caterpillar Engine Simulator 3406E-10

 3406E Application
Optional Simulator Screen Display
Cruise ON/OFF Switch

The cruise control ON/OFF switch is located on the physical panel, and simulator
screen 1 only (Brake/Clutch Cruise Panel). The switch is a two position toggle.
When the switch is ON (up position), cruise control is active. When the switch is
OFF (down position), cruise control is inactive.

Cruise Set/Resume Switch

The cruise set/resume switch is located on the physical panel, and simulator
screens 1 & 3 (Brake Clutch Cruise & Cab PTO Panels). The switch is a three
position momentary toggle. The switch can be selected for SET or RESUME for
cruise control and operate as an automotive-style cruise control or as a PTO RPM
Increase/Decrease for PTO Cab Switch configuration.

Panel 2-Retarder A/C Panel

Low
I I I
Med
0 0 0
Hi
Brake
Retarder Retarder A/C High
Level Pressure

Retarder ON/OFF

The retarder ON/OFF switch is located on the optional simulator screen 2

(Retarder A/C Panel). The switch is a two position toggle. When the switch is On
(closed) it enables the retarder to be set. When it is Off (open), this is an override
and the retarder is inactive.

Retarder Level Switch

The retarder level switch is located on the optional simulator screen 2 (Retarder
A/C Panel). The switch is a three position toggle. When the switch is LOW (up
position), MED (middle position), or HI (down position), the retarder level lamp
will illuminate when the retarder is using the engine for braking. If the retarder
ON/OFF switch is OFF, this switch is disabled.

The Caterpillar Engine Simulator 3406E-11

 3406E Application
Optional Simulator Screen Display
A/C High Pressure Switch

The A/C high pressure switch is located on the optional simulator screen 2 (Retarder
A/C Panel). The switch is a two position toggle. When this switch is closed (down
position), the fan will turn ON to simulate the air conditioner is active. When the
switch is open (up position), the fan should be OFF.

Set
I I I

0 0 0
Resume
Brake Clutch Cab Cruise
PTO

Panel 3- Cab PTO Panel

Cab PTO ON/OFF Switch

The PTO ON/OFF switch is located on the optional simulator screen 3 (Cab PTO
Panel).

NOTE: Cab Switches must be programmed into the ET Configuration screen for
PTO parameter.

The switch is a two position toggle. When this switch is ON (up position), PTO is
active. If the switch is OFF (down position), PTO is inactive. This is also an override
switch to the PTO RPM increase\decrease switch.

Cruise Set/Resume Switch - When the switch is toggled to increase (up position),
engine speed will increase to programmed PTO to Set Speed. When the switch is
toggled to decrease (down position), engine speed will return to programmed Low
Idle speed. If neither position is selected, then the engine speed will remain at
programmed engine speed. If the PTO On/Off switch is OFF, then this switch is
disabled.

The Caterpillar Engine Simulator 3406E-12

 3406E Application
Optional Simulator Screen Display

Increase
I I I

0 0 0
Decrease
Brake Clutch
Remote PTO
PTO

Panel 4- Remote PTO Panel

Remote PTO ON/OFF Switch

The PTO ON/OFF switch is located on the optional simulator screen 4 (Remote PTO
Panel) and simulates applications with a switch in a location other than the cab.

NOTE: Remote Switches must be programmed into the ET Configuration screen for
PTO parameter.

The switch is a two position toggle. When this switch is ON (up position), PTO is
active. If the switch is OFF (down position), PTO is inactive. This is also an override
switch to the PTO RPM increase\decrease switch.

PTO RPM Increase/Decrease

This switch is located on the optional simulator screen 4 (Remote PTO Panel). The
switch is a three position, momentary toggle. When the switch is toggled to increase
(up position), engine speed will increase to programmed PTO to Set Speed. When the
switch is toggled to decrease (down position), engine speed will return to
programmed Low Idle speed. If neither position is selected then the engine speed will
remain at programmed engine speed. If the PTO On/Off switch is OFF, then this
switch is disabled.

The Caterpillar Engine Simulator 3406E-13

 3406E Application
Instructor Screens
Instructor Screens
The instructor's interface will consist of two screens: the problem editor and the
lesson editor. The PC allows the instructor control over simulator functions and
faults. The instructor will be able to set up faults and operating conditions and save
them for later retrieval and use. This allows tremendous flexibility in designing
unique class work.

Problem Editor

The instructor can manipulate fault conditions and store the conditions as problems
by using the problem editor. Problems can be harness or component related, and can
be static or time dependent. Problems can also contain more than one fault. Harness
faults are typically open circuits or shorts to ground. Faulted components may be
open, shorted, or over-ridden to marginal values depending on instructor preferences.
Time dependent faults can be intermittent or delayed, and of variable duration.
Comments can be attached to a problem in the form of symptoms, which are for
student reference, or descriptions, which are for the instructor's reference only.

List of Fault Conditions

The following list contains all information required for the fault conditions table
available in the problem editor.

1. Fault Times:
If Fault Times are listed as available in the following tables then,
Intermittent Times are Minimum, Maximum & Duration - User can enter
from 0 to 99:99 min:sec in 1 second increments.
2. Delay Time:
User can select 0:0 to 15:00 min:sec in 1 second increments.
3. Override Ramp Times:
On or Off - User can enter from 0 to 99:99 min:sec in 1 second increments.
4. Defaults Button:
Pressing the default button returns all values to Zero. Overrides should be
available as a value as well as percentage for certain parameters. These
parameters are noted in the following.

¥An example would be overriding oil pressure by typing in an oil pressure value
in kPa versus selecting a percentage on the slider bar.

5. Fault Conditions

The Caterpillar Engine Simulator 3406E-14

 3406E Application
Instructor Screens
Sensor Faults:
NORM=Normal operation, STG=Short to Ground, OPN=Open Circuit,
OVR=Override.

User can override parameter to a specific value, OR... user can override parameter
from 0% to 200%, where 100% is normal.

Harness Faults:
NORM =Normal operation, STG=Short to Ground, STB=Short to +Battery,
OPN=Open Circuit, OTH=Other.

6. Fault Times - Y = Available, N= Not Available.

FAULT CONDITIONS TABLE
SENSOR FAULT HARNESS FAULT
NORM STG OPN OVR NORM STG STB OPN OTH
Analog Power X X X
Atmospheric Press X X X X
Cylinder 1 High X X
Coolant Temp X X X X X X
Intake Manifold X X X X X X
Air Temperature
Fuel Temperature X X X X
Cylinder 2 Hi Side X X
Cylinder 3 Hi Side Short
to Low Side X X
Cylinder 4 Hi Side X X
Cylinder 5 Low Side X X
Key switch Input X
Oil Pressure X X X X
Other Sensors -AnalogX X X X
Speed Timing and
Throttle Return X X
Speed Timing Power X X
Speed/Timing Signal X X
Throttle Sensor Power X X
Throttle Signal X X
Boost Pressure (TOut)X X X X

The Caterpillar Engine Simulator 3406E-15

 3406E Application
Instructor Screens
Lesson Editor

After storing problems in the problem editor, the lesson editor is used to group the
problems into lessons. Lessons can then be accessed by the student from the
simulator screen.

Programmable Monitoring System Lessons

Specific lessons can be designed to allow the student to program the engine
monitoring system. For the On-Highway Truck Engine, a comprehensive,
programmable monitoring system allows the ECM to take various actions if a sensor
parameter is out of range.

For example, the ECM can provide a warning, derate engine power, or shut the
engine down, if the oil pressure is too low. Flexibility is provided to the end user (or
dealer) to change certain set-points in the monitoring system to tailor the ECM
operation to a particular need.

The problem editor and lesson editor can be used to provide an example lesson so
students can witness the effects of programmed warnings, derates and shutdowns.

Lessons can be designed for the following parameters:

n Low oil pressure

n High coolant temperature
n Low coolant temperature
n High Intake Air Manifold Temperature

NOTE: Refer to the Troubleshooting Guide for additional information.

The Caterpillar Engine Simulator 3406E-16

 3406E Application
Instructor Screens
High Coolant Temperature Override Lesson

Use the override and change value to 4.3-4.4VDC. This should create high coolant
temperature. If Caterpillar Engine Monitoring is programmed to OFF, the fault and
event are logged. If Caterpillar Engine Monitoring is set to WARNING, the warning
lamp comes on.

If DERATE is set, the warning lamp flashes, power and vehicle speed are limited to
160 hp and 45 mph respectively.

If SHUTDOWN is programmed, the warning lamp flashes, power and vehicle speed
are limited to 160 hp and 45 mph respectively. After 20 seconds, if conditions
continue then the engine will shutdown.

High Intake Manifold Air Temperature Lesson

Use the override and change value to 3.96 VDC. This should create high intake
manifold air temperature. If Caterpillar Engine Monitoring is programmed to OFF,
the fault and event are logged. If Caterpillar Engine Monitoring is set to WARNING,
DERATE, OR SHUTDOWN the warning lamp comes on.

The Caterpillar Engine Simulator 3406E-17

769D
Application Guide

769D Off-Highway Truck Hauling Unit

The 769D Off-Highway Truck application software training module for the
Caterpillar Electronic Training Aid program is the first 3400E HEUI engine
simulator. Use this module to train on the 3408E HEUI engine and the
EPTC-II power train system for the 769D Off-Highway hauling vehicle.
Refer to EPTC II Upgrade TCA9703-01 Service Bulletin.
The following pages include specifications for Simulator setup and general
information.
NOTE: A Phase II hardware upgrade is necessary to run this application.
Ensure your hardware is upgraded to Phase II. Refer to Engine Simulator
Phase II Upgrade (Removal) TCA9601-01 and (Install) TCA9601-02
Service Bulletins. A version 5 HC11 microprocessor chip is required to
ensure proper operation and the Timing Calibration can be performed as
well. Refer to HC-11 Upgrade v5.01 TCA9703-02 Service Bulletin.

The Caterpillar Engine Simulator 769D-1

 769D Application
769D (HEUI) System Specifications
769D (HEUI) System Specifications
ECM 106-1184

ECM Mounting
Grommet Part No. (8) 8T9655
Bushing Part No. (4) 6I1418
Washer Part No. (8) 9N0869

Application/ECM Harness Part 138-0393

Number Connects ECM (J1 & J2) to
Training Aid Ports (A & B)

Personality Module (Flash File) 140-8539

Part No.

ECM Power Selector 24 VDC

Engine Panel Voltage Selector Set to local voltage
(115 VAC or 220 VAC)

Customer Specified Parameter - TAID1234

Vehicle ID #

Customer Specified Parameter - 99C000001

Eng Serial #

Recommended Electronic Service Electronic Technician (ET)

Tool V1.6 or greater (JERD2124)

Required Data Link Harness CAT or Universal

7X1570 or 139-4166

Required PC (9303) to Panel J1, J2, J3, RS-232 (for Engine)

Connector Cables J4, J5 (for Transmission)

Application Software SERV7002(V2.1)

Application Appendix SEBV7002(V2.1)

CAT Monitoring System 151-2764 (TA9710)

Training Aid Panel

The Caterpillar Engine Simulator 769D-2

 769D Application
ECM Harness Port Connections
ECM Harness Port Connections

Connector B Connector A Timing Cal Connector

Dashboard for the 769D Application

Quad Gauge Module Main Module
Message Center

Speedometer/Tachometer Module

The Caterpillar Engine Simulator 769D-3

 769D Application
Engine Panel Sensor Locations
Engine Panel Sensor Locations

Speed Timing 2 Speed Timing 1

Oil
Coolant
Temperature
Temperature

Fuel
Turbo Outlet Temperature

Atmospheric
Turbo Inlet
Pressure

Fan Speed Sensor

Oil Pressure

Injection
Actuation
Pressure

Instrument Panel

Tachometer Ground
Level
Ether Manual Shutdown Throttle Load

Lamp Throttle Ignition Crank

User Shutdown
Backup

The Caterpillar Engine Simulator 769D-4

 769D Application
Electrical Control System Diagram 3408 HEUI
Electrical Control System Diagram 3408 HEUI
ADEM II
Electronic
Injectors Module
Control
8 or 12
Ground Bolt Disconnect Switch -
24V
Main Key
+5 Amp Power Relay +
Injection Actuation Pressure Machine Breaker Switch
Control Valve Interface
Connector
Primary Speed/Timing Sensor
TDC
Throttle Sensor
Hydraulic Pressure Sensor Service Accelerator Pedal

Secondary Speed/Timing Sensor Throttle Back-up Ground Level

Shutdown and User Defined Shutdown
Coolant Temperature Sensor
Ether Switch
Turbo Outlet Pressure Sensor Turbo Inlet Pressure Sensor
Atmospheric Pressure Sensor Prelubrication System
Engine Fan Control
Oil Pressure Sensor Fan
CAT Data Link
Hydraulic Oil Temperature Sensor Electronic Service Tool
EPTCII Transmission Control
Fuel Temperature Sensor
Auto Retarder Control
Coolant Flow Switch
Instrument
Panel

Harness Connector Pin Location

1 2 3 4 5 6 7 8 9 10

15 16
11 20

21 30
25 26

31 32 33 34 35 36 37 38 39 40

NOTE: Refer to 769D Electronic Troubleshooting manual for pin designations.

The Caterpillar Engine Simulator 769D-5

 769D Application
Model View (Top) with Sensor Location
Model View (Top) with Sensor Location
Injection Actuation Engine Oil Engine Oil
Grounding Stud Pressure Contol Valve Temperature Pressure Atmospheric
Sensor Sensor Pressure
Sensor

Injector Secondary
Connector Speed/Timing
Sensor

Fuel
Temperature
Sensor
Machine Primary
40 Pin Speed/Timing
Connector
Sensor
Turbo Outlet
Pressure Sensor

Coolant
Temperature
Sensor
Injection Top Center Electronic Coolant
Actuation Probe
Pressure Control FlowSwitch
Connector Module
Sensor

Fuel System Diagram 3408E/3412E HEUI

Engine Oil Filtered
Temperature Oil Pressure
To Lubrication
Sensor Sensor
System
Cooldown
Circuit
High Pressure
Cold Start Oil Manifold
Oil High Injection
Fuel Temperature
Reservoir Pressure Pressure
Sensor
Oil Pump Actuation
High Pressure Sensor
Oil Manifold
Oil
Filter
Injection
Actuation Oil Fuel
Pressure
Cooler Transfer HEUI
Control
Valve Pump
Lubrication Secondary
Oil Pump Fuel Filter Pressure
Primary
Fuel Filter Regulation
Water Valve
Separater

Oil Pump
Fuel
Tank

The Caterpillar Engine Simulator 769D-6

 769D Application
Using the 769D Application Training Aid
Using the 769D Application Training Aid
The 769D Off-Highway Truck Training Aid is intended to be used by Service
Training and dealers worldwide to train mechanics and other service personnel how to
troubleshoot electronic systems using the application Troubleshooting Guide and
Caterpillar Electronic Service Tools.
The Simulator Panel(s) provide the necessary components (hardware and functions)
to simulate the vehicle operation using a production ECM with proper harnessing,
“real” sensors, and injector solenoid loads. The PC interface with simulator screen
and connection to the Caterpillar Monitoring System panel simulates an engine or
vehicle to allow all functional operation (throttle, transmission gear selection,
keyswitch, monitoring system, etc.).
The PC instructor screen allows Service Training or dealer training instructors to
program faults, “bugs”, etc. into the simulator to illustrate typical field problems
encountered by service technicians such as single or multiple sensor signal faults
(shorts, opens, intermittent & override), and wiring harness faults (shorts or opens).
The instructor also has the capability of “tweaking performance” or creating
abnormal operating conditions.
The connection to Electronic Technician via integral service tool connector on the
front face of the simulator provides “real-time” on-board diagnostics to aid the
instructors and students alike to interact in a classroom setting (with repeatable
lessons) to provide standardized teaching and learning methods.
Simulation Control
Two buttons will allow the student to select between On-screen Control and Physical
Panel Control. An ignition key start switch is simulated. Activating the buttons
“OFF”, “RUN” and “START” on the screen will place the switch in the three
positions and the engine start sequence begins. In addition, when the start button is
released the keyswitch will return to the “RUN” position. Once “START” has been
selected, the keyswitch must be placed in the “OFF” position before selecting
“START” again to restart the engine.
Engine Prelubrication
This system provides a means to automatically prelubricate the engine before
cranking. The parameter must be programmed to enable prelubrication for this
function. Turning the keyswitch to “Start” position activates prelubrication feature
and a signal is sent from EPTC II to engage start motors. If there is no communication
with EPTC II over the data link the engine control will disable the feature, thus
allowing the engine simulator to operate in stand-alone mode without prelubrication.

The Caterpillar Engine Simulator 769D-7

 769D Application
Using the 769D Application Training Aid
Throttle
The simulation control panel has slider bars to control both the engine load and
throttle position. A standard throttle system is simulated that duplicates the truck
throttle system. When the throttle position slider bar (or potentiometer on physical
panel) are at low position, the duty cycle output represents low idle. When the throttle
position slider (or potentiometer on physical panel) are at high position, the duty
cycle output represents rated high idle.
Ether System
An ether injection system is an option on the 3408/12E HEUI engine to help the
engine start in cold temperatures. The ECM controls one relay to inject ether. The
ether injector system is simulated on the PC screen by changing the color of the
solenoid when it is energized. The parameter must be programmed to enable ether for
this feature to function.
Cat Monitoring System (CMS)
The 769D application has CMS for its monitoring package. Refer to page 3 dashboard
for 769D application. The 151-2764 ETA panel is required to ensure all operation and
monitoring parameters function properly with the simulator. If you choose not to
utilize the 151-2764 panel with your set up, the simulation may not operate to
your satisfaction. Only the engine related switches and slide bars are displayed on
the training aid simulation screen. All other monitored features including gauges,
tachometer, speedometer, lamps, and indicators are displayed on the CMS panel.
The CMS consists of operator switches on front panel, and switches and
potentiometers on rear of the CMS physical panel. The CMS physical panel provides
production gauge modules and main module for monitoring.
Instructor Screens
The instructor's interface will consist of two screens: the problem editor and the
lesson editor. The PC allows the instructor control over simulator functions and
faults. The instructor can set up faults and operating conditions and save them for
later retrieval and use. This allows tremendous flexibility in designing unique class
work. Compiled lessons can be accessed while in the simulator screen. When the
lesson is loaded, the lesson name and problem number will be displayed. The students
will be able to toggle between problems at their own pace.

The Caterpillar Engine Simulator 769D-8

 769D Application
Using the 769D Application Training Aid
Problem Editor
The instructor can manipulate fault conditions and store the conditions as problems
by using the problem editor. Problems can be harness or component related, and can
be static or time dependent. Problems can also contain more than one fault. Harness
faults are typically open circuits or shorts to ground. Faulted components may be
open, shorted, or over-ridden to marginal values depending on instructor preferences.
Time dependent faults can be intermittent or delayed, and of variable duration.
Comments can be attached to a problem in the form of symptoms, which are for
student reference, or descriptions, which are for the instructor's reference only.
Lesson Editor
After storing problems in the problem editor, the lesson editor is used to group the
problems into lessons. Lessons can then be accessed by the student from the simulator
screen. Specific lessons can be designed to allow the student to troubleshoot the
system and to take various actions if parameter are out of range. For example, the
ECM will provide one of the levels (warning, derate power, or shutdown), if the oil
pressure is too low.
Fault Conditions
The following list contains all information required for the fault conditions available
in the problem editor. If Fault Times are listed as available in the Fault Condition
tables, then Fault Times must use the following values.
Intermittent Times
a)Minimum - User can enter from 0 to 99:99 min:sec in 1 sec. increments.
b)Maximum - User can enter from 0 to 99:99 min:sec in 1 sec. increments.
c)Duration - User can enter from 0 to 99:99 min:sec in 1 sec. increments.
Delay Time
User can select 0:0 to 15:00 min:sec in 1 sec. increments.
Override Ramp Times
a)On - User can enter from 0 to 99:99 min:sec in 1 sec. increments
b)Off - User can enter from 0 to 99:99 min:sec in 1 sec. increments
Default Buttons: Pressing the default button returns all values to zero.
Overrides
Overrides should be available as a value, as well as percentage for certain parameters.
These parameters are noted in the following fault tables. An example would be
overriding oil pressure by typing in an oil pressure value in kPa versus selecting a
percentage on the slider bar.

The Caterpillar Engine Simulator 769D-9

 769D Application
Fault Condition Table Legend
Fault Condition Table Legend
Use the legend to read the fault condition tables on the following pages for sensor
faults and harness faults available for this application.
NORM = Normal Operation
D = Default
X = Available
Blank = Not Available
STG = Short to Ground
OPN = Open Circuit
STB = Short to Battery
OTH = Other
Note: User can override parameters to specified values, OR from 0% to 200% of
actual value using the override slider bar.

The Caterpillar Engine Simulator 769D-10

 769D Application
Fault Condition Table (Sensors)
Fault Condition Table (Sensors)
Fault Condition Sensor Sensor Sensor Sensor Other Fault
Normal STG Open Override Times

Analog Power D YES

Analog Power D YES

Atmospheric

Atmospheric Pressure D X X 0-5VDC* YES

CAT Data Link D YES

Cyl # 1 High Side D YES

Cyl # 2 High Side D YES

Cyl # 3 Short to Low Side D YES

Cyl # 4 High Side D YES

Cyl # 5 Low Side D YES

Oil Temperature D X 0-5VDC* YES

IAPC Pressure D X 0-5VDC* YES

Coolant Temperature D X 0-5VDC* YES

Fuel Temperature D X 0-5VDC* YES

Oil Pressure D X 0-5VDC* YES

Other Sensors D YES

Analog Only

Keyswitch In (+Battery) D YES

Speed Timing & D YES

Throttle Return

Speed Timing Power D YES

Speed Timing Signal D YES

Throttle Sensor Power D YES

Throttle Signal D YES

Turbo Inlet Analog D YES

Return

Right Turbo Inlet D X X 0-5VDC* YES

Pressure

Turbo Outlet Pressure D X 0-5VDC* YES

(Boost)

* 0-5VDC OR 0% - 200%

The Caterpillar Engine Simulator 769D-11

 769D Application
Fault Condition Table (Harness)
Fault Condition Table (Harness)
Fault Condition Harness Harness Harness Harness Other Fault
Normal STG STB Open Times

Analog Power D X YES

Analog Power D X YES

Atmospheric

Atmospheric Pressure D YES

CAT Data Link D X YES

Cyl # 1 High Side D X YES

Cyl # 2 High Side D X YES

Cyl # 3 Short to Low Side D X YES

Cyl # 4 High Side D X YES

Cyl # 5 Low Side D X YES

Oil Temperature D YES

IAPC Pressure D YES

Coolant Temperature D X YES

Fuel Temperature D YES

Oil Pressure D YES

Other Sensors D X YES

Analog Only

Keyswitch Input D X YES

Speed Timing & D X YES

Throttle Return

Speed Timing Power D X YES

Speed Timing Signal D X YES

Throttle Sensor Power D X YES

Throttle Signal D X YES

Turbo Inlet Analog D X YES

Return

Right Turbo Inlet D YES

Pressure

Turbo Outlet Pressure D YES

(Boost)

The Caterpillar Engine Simulator 769D-12

777C
Application Guide

777C Off-Highway Truck

The 777C Off-Highway Truck application is a software training module
for the Caterpillar Engine Simulator’s Electronic Training Aid program.
Use this module to train on the 3508 engine’s EUI system.

The following pages include specifications for Simulator setup and

general information.

The Caterpillar Engine Simulator 777C-1

 777C Application
EUI System Specs
EUI System Specs
ECM 9X9972
ECM Harness 110-4541
ECM Harness Port Connect to Port A
EUI Parameters Serial Number: 7YG00001
Application Serial Number:
4TJ00001
Personality Module 124-8690
Engine Component Panel Set to local voltage
Voltage Selector (115Vac OR 220Vac)
ECM Power Selector 24Vdc
Required Connector Cables J1, J2, J3, RS232

Dashboard for the 777C Application

The Caterpillar Engine Simulator 777C-2

 777C Application
Engine Panel Sensor Locations
Engine Panel Sensor Locations

Speed/Timing
Sensor
Coolant
Temperature
Sensor

Atmospheric
Turbo Outlet Pressure
Pressure Sensor Sensor

Turbo Inlet Oil Pressure

Pressure Sensor Sensor

Instrument Panel

Check Elevated Low Throttle

Load Ignition
Engine Idle Enable Backup

Test Remote Diagnostic

Panel Shutdown Enable Throttle Crank

The Caterpillar Engine Simulator 777C-3

 777C Application
Engine Panel Sensor Locations
Electrical Control System Diagram
Electronic Control
Machine Battery
Module
J3-10 P3-10 and Charging System
-
Main Power 24V
Keyswitch
Relay +
Engine Block
Electronic
Ground Bolt
Unit
Injectors
Mach.
P1 Conn.
Communication/Service Link
Communication
Timing Adapter/ECAP
Engine Speed Timing Sensor P26 Claibration Service Tool
P19 J19
Connector
Elev. Low Idle Enable Transmission
Engine Coolant Temperature Sensor Control
J20 P20
Throttle Backup/ Throttle
Diagnostic Enable
Engine Oil Pressure Sensor
P21 J21
Atmospheric Pressure Check Engine Lamp
Turbo Comp. Outlet Pressure Sensor P27 J27
P22 Air Filter Lamp
J22

Turbo Comp. Inlet Pressure Sensor Oil Pressure Engine Overspeed Lamp
P25 J25
Coolant Temperature
Engine Overspeed Alarm
Ground Level Lhutdown Switch Engine On
EMS

Harness Connector Pin Location

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28

29 30 31 32 33 34 35 36 37 38 39 40 41 42

43 44 45 46 47 48 49 50 51 52 53 54 55 56

57 58 59 60 61 62 63 64 65 66 67 68 69 70

The Caterpillar Engine Simulator 777C-4

785B
Application Guide

785B Off-Highway Truck

The 785B Off-Highway Truck application is a software training module for
the Caterpillar Engine Simulator’s Electronic Training Aid program.
Use this module to train on the 3512 engine’s EUI system.

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

Note: When changing Personality Modules, refer to the procedure in the

Troubleshooting Guide.

The Caterpillar Engine Simulator 785B-1

 785B Application
EUI System Specs
EUI System Specs
ECM 9X9971
ECM Harness 125-4326
ECM Harness Port Connect to Ports A & B
EUI Parameters Serial Number: 2PK00001
Machine Serial Number:
6HK00001
Personality Module 124-8689
Engine Component Panel Set to local voltage
Voltage Selector (115Vac OR 220Vac)
ECM Power Selector 24Vdc
Required Connector Cables J1, J2, J3, RS232
Blue Grommets 8 required 9X9896
Metal Spacers 4 required 9X9838

Dashboard for the 785B Application

The Caterpillar Engine Simulator 785B-2

 785B Application
Engine Panel Sensor Locations
Engine Panel Sensor Locations

Coolant
Temperature Speed/Timing
Sensor Sensor

Turbo Outlet
Pressure Sensor Atmospheric
Pressure
Sensor

Turbo Inlet Left

Pressure Sensor
Oil Pressure
Sensor

Turbo Inlet Right

Pressure Sensor

Instrument Panel

Check Remote Diagnostic

Shutdown Load Ignition
Engine Enable

Test Throttle
Panel Throttle Crank
Backup

The Caterpillar Engine Simulator 785B-3

 785B Application
Engine Panel Sensor Locations
Electrical Control System Diagram 3512 and 3516 EUI
ECM
Ground Stud
-
24V
+
Timing Cal
Connector P1 Communication
Adapter/ECAP
Engine Harness Service Tool
Speed/Timing Sensor
Machine
Coolant Temperature Sensor Connector P2 J2
Auto Retard Transmission
Control Control
Oil Pressure Sensor Atmospheric Pressure Sensor
Throttle
Turbo in Left Tressure Sensor
Check Engine Lamp
Turbo in Right Pressure Sensor

Engine Overspeed
Turbo Out Pressure Sensor Lamp and Buzzer
Inlet Air Restriction Lamp

Diagnostic High Coolant Temp

Ground Level Shutdown Switch Enable
Switch Low Ol Pressure

Throttle Aftercooler Engine Running

Backup Temp Switch
Switch

ECM Harness Port Connections

Timing Cal Connector

Connector B Connector A

The Caterpillar Engine Simulator 785B-4

789B
Application Guide

789B Off-Highway Truck

The 789B Off-Highway Truck application is a software training module for
the Caterpillar Engine Simulator’s Electronic Training Aid program. Use
this module to train on the 3516 engine’s EUI system.

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

Note: When changing Personality Modules, refer to the procedure in the

Troubleshooting Guide.

The Caterpillar Engine Simulator 789B-1

 789B Application
789B Off-Highway Truck
EUI System Specs
ECM 9X9971
ECM Harness 125-4326
ECM Harness Port Connect to Ports A & B
EUI Parameters Serial Number: 4WJ00001
Machine Serial Number:
7EK00001
Personality Module 124-8688
Engine Component Panel Volt- Set to local voltage (115Vac OR
age Selector 220Vac)
ECM Power Selector 24Vdc
Required Connector Cables J1, J2, J3, RS232
Blue Grommets 8 required 9X9896
Metal Spacers 4 required 9X9838

Dashboard for the 789B Application

The Caterpillar Engine Simulator 789B-2

 789B Application
Engine Panel Sensor Locations
Engine Panel Sensor Locations

Coolant
Temperature Speed/Timing
Sensor Sensor

Turbo Outlet
Pressure Sensor Atmospheric
Pressure
Sensor

Turbo Inlet Left

Pressure Sensor
Oil Pressure
Sensor

Turbo Inlet Right

Pressure Sensor

Instrument Panel

Check Remote Diagnostic

Shutdown Load Ignition
Engine Enable

Test Throttle
Panel Throttle Crank
Backup

The Caterpillar Engine Simulator 789B-3

 789B Application
Engine Panel Sensor Locations
Electrical Control System Diagram 3512 and 3516 EUI
ECM
Ground Stud
-
24V
+
Timing Cal
Connector P1 Communication
Adapter/ECAP
Engine Harness Service Tool
Speed/Timing Sensor
Machine
Coolant Temperature Sensor Connector P2 J2
Auto Retard Transmission
Control Control
Oil Pressure Sensor Atmospheric Pressure Sensor
Throttle
Turbo in Left Tressure Sensor
Check Engine Lamp
Turbo in Right Pressure Sensor

Engine Overspeed
Turbo Out Pressure Sensor Lamp and Buzzer
Inlet Air Restriction Lamp

Diagnostic High Coolant Temp

Ground Level Shutdown Switch Enable
Switch Low Ol Pressure

Throttle Aftercooler Engine Running

Backup Temp Switch
Switch

ECM Harness Port Connections

Timing Cal Connector

Connector B Connector A

The Caterpillar Engine Simulator 789B-4

793B
Application Guide

793B Off-Highway Truck

The 793B Off-Highway Truck application is a software training module for
the Caterpillar Engine Simulator’s Electronic Training Aid program. Use
this module to train on the 3516 engine’s EUI system.

The following pages include specifications for simulator setup and

general information.

Note: When changing Personality Modules, refer to the procedure in the

Troubleshooting Guide.

The Caterpillar Engine Simulator 793B-1

 793B Application
EUI System Specs
EUI System Specs
ECM 9X9971
ECM Harness 125-4326
ECM Harness Port Connect to Ports A & B
EUI Parameters Serial Number: 4WJ00001
Machine Serial Number: IHL00001
Personality Module 124-8687
Engine Component Panel Set to local voltage
Voltage Selector (115Vac OR 220Vac)
ECM Power Selector 24Vdc
Required Connector Cables J1, J2, J3, RS232
Blue Grommets 8 required 9X9896
Metal Spacers 4 required 9X9838

Dashboard for the 793B Application

The Caterpillar Engine Simulator 793B-2

 793B Application
Engine Panel Sensor Locations
Engine Panel Sensor Locations

Coolant
Temperature Speed/Timing
Sensor Sensor

Turbo Outlet
Atmospheric
Pressure Sensor
Pressure
Sensor

Turbo Inlet Left Oil Pressure

Pressure Sensor Sensor

Turbo Out High

Pressure Sensor
Turbo Inlet Right
Pressure Sensor

Instrument Panel

Check Remote Diagnostic

Shutdown Load Ignition
Engine Enable

Test Throttle
Panel Throttle Crank
Backup

The Caterpillar Engine Simulator 793B-3

 793B Application
Engine Panel Sensor Locations
Electrical Control System Diagram 3512 and 3516 EUI
ECM
Ground Stud
-
24V
+
Timing Cal
Connector P1 Communication
Adapter/ECAP
Engine Harness Service Tool
Speed/Timing Sensor
Machine
Coolant Temperature Sensor Connector P2 J2
Auto Retard Transmission
Control Control
Oil Pressure Sensor Atmospheric Pressure Sensor
Throttle
Turbo in Left Tressure Sensor
Check Engine Lamp
Turbo in Right Pressure Sensor

Engine Overspeed
Turbo Out Pressure Sensor Lamp and Buzzer
Inlet Air Restriction Lamp

Diagnostic High Coolant Temp

Ground Level Shutdown Switch Enable
Switch Low OIl Pressure

Throttle Aftercooler Engine Running

Backup Temp Switch
Switch

ECM Harness Port Connections

Timing Calibration Connector

Application Connector

Timing Cal Connector

Connector B Connector A

The Caterpillar Engine Simulator 793B-4

D11N
Application Guide

D11N Track Type Tractor

The D11N Track Type Tractor Application is a software training module for
use with the Caterpillar Engine Simulator Electronic Training Aid program.
Use this module to train on the D11N 3500 engine electronic system.

The following pages include specifications for Simulator setup and

general information.

NOTE: A Phase II hardware upgrade is necessary to run this application.

Examine your Training Aid Engine Simulator Panel to ensure it is
upgraded to Phase II. A version 5 HC11 microprocessor chip is
recommended, but not required, to ensure the Timing Calibration can be
performed as well.

The Caterpillar Engine Simulator D11N-1

 D11N Application
Engine System Specifications:
Engine System Specifications:
ECM Part Number 9X9972
ECM Mounting
Grommet Part Number (8) 8T9655
Bushing Part Number (4)6I1418
Washer Part Number (8)9N0869
Application/ECM Harness Part Number 124-2451
Connects ECM (J1) to
Training Aid Port (A)
Personality Module Part Number 1354540-01
ECM Power Selector 24VDC
Customer Specified Parameter Vehicle ID # 4HK00001
Customer Specified Parameter Engine Serial # 7YG00001
Recommended Electronic Service Tool Electronic Technician (ET)
Comm. Adapter to Service Tool Harness 7X-1425
Required Data Link Harness 7X-1570
Electronic Trouble Shooting Guide for D11N SENR5590

Service Manual for Computerized Monitoring SENR55247

System

The following list contains the necessary Caterpillar part numbers for ordering the
CMS Monitoring System and for assembling the associated harness to
operate the CMS Monitoring System. Refer to attachment “A” on page 10 in this
application guide for information regarding Computerized Monitoring System
(CMS.) panel pinout chart.

Description Cat Part No. Qty

CMS Display Panel for D11N 132-9896 1
CMS Overlay Film for D11N 3E-0466 1
Deutsch 70 pin A-keyed connector 9X4391 1
Deutsch 40 pin rectangular connector 9X0141 1

The Caterpillar Engine Simulator D11N-2

 D11N Application
Engine System Specifications:

Simulator Dash Panel for the D11N Application (EMS)

Simulator Dash Panel for the D11N Application (CMS)

The Caterpillar Engine Simulator D11N-3

 D11N Application
Engine Panel Sensor Locations
Engine Panel Sensor Locations

Coolant
Temperature Speed/Timing
Sensor Sensor

Turbo Outlet
Pressure Sensor Atmospheric
Pressure
Sensor

Turbo Inlet Left Oil Pressure

Pressure Sensor Sensor

Turbo Inlet Right

Pressure Sensor

Instrument Panel

Check Diagnostic Crank w/o Throttle

Engine Enable Injectors - High Idle Load Ignition

User-defined Test Throttle

Shutdown Panel - Low Idle Throttle Crank

The Caterpillar Engine Simulator D11N-4

 D11N Application
Engine Panel Sensor Locations

The Caterpillar Engine Simulator D11N-5

 D11N Application

The Caterpillar Engine Simulator D11N-6

 D11N Application
Application Information
Application Information
Application Screens
The application screen is the first screen displayed after selecting an application from
the main menu. It displays the picture of the application machine. Information screens
have an engine diagram with sensor locations, system diagrams, and a description of
system components.

Simulator Screens
The simulator screen for the EMS provides a control panel with application specific
gauges, switches, and accessories. It contains, a tachometer, a coolant temperature
gauge, an oil pressure gauge, the decelerator and load slide bars, a gear selector but-
ton, and the associated switches. It has two warning lamps, one for the coolant tem-
perature and one for the oil pressure. These lamps will turn on if the parameters
exceed the normal operating range.

The D11N application has CMS for its monitoring package. Only the engine related
switches and slide bars are displayed on the training aid simulation screen. All other
features including the coolant temperature and oil pressure gauges, tachometer, air fil-
ter restriction, check engine light, CMS master fault lamp, service code light, and the
gear indicator are displayed on the CMS panel.

The CMS consists of the simulator screen, and the CMS physical panel. The CMS
physical panel provides gauges, monitoring, and computer screen with the associated
switches to operate CMS.

Compiled lessons can be accessed while in the simulator screen. When the lesson is
loaded, the lesson name and problem number will be displayed. The students will be
able to toggle between problems at their own pace.

Simulation Control
The simulation control panel has two slider bars to control the load and the decelera-
tion. A button is provided to start the engine simulation and a momentary switch is
provided to stop the engine simulation. There are also up and down arrows for chang-
ing the desired gear.

The Caterpillar Engine Simulator D11N-7

 D11N Application
Application Information
System Control
A switch is used for the throttle. The switch allows the user to go high idle (1980
RPM), low idle (650 RPM). The decelerator is used to reduce the engine speed with-
out adjusting the throttle switch.
The Crank w/o Inject feature allows the user to disable the injection, while still hav-
ing the ability to crank the engine for troubleshooting purposes. This feature is
enabled by turning the switch no.3 on the physical panel to DOWN position. Note
that the screen toggles between Run and Crank with the flipping of this switch.

Timing Calibration
The timing calibration cable must be installed before running the engine to simulate
the permanent timing calibration sensor. If the cable is not installed the engine will
run but the ET will display an abnormal timing calibration.

Transmission Model
The transmission is simulated by the software. The software version will affect the
machine in respect to engine load and transmission output speed. The D11N training
aid does not use control throttle shifting.

The Caterpillar Engine Simulator D11N-8

 D11N Application
Application Information
Configure the Service Tool
The ET service tool has to be configured to work with EMS or the CMS panel as the
case may be. To configure the ET, perform the following procedure.

1. Go into the D11N application.

2. Click on EMS or the CMS option.

Options

Panel Type

EMS Panel

CMS Panel

This form allows you to choose which options will be used with the
vehicle you have selected. You must select a panel type to use.

3. Go into the ET service tool.

4. Make sure that ET is communicating with the ECM, and no error messages are
displayed on the ET screen.
5. Click on the Configuration button.

A configuration screen will appear with all the relevant information including the fact
that ET is either configured to the EMS or the CMS mode.

6. Click on the monitoring System

7. Click on the Change button which is located on the lower left side of the ET
screen.

A Change Parameter Value window will appear.

8. Pull down the New Value menu.

9. Select EMS or CMS as the case may be.
10. Click OK.

The configuration screen will display to the selected mode.

The Caterpillar Engine Simulator D11N-9

 D11N Application
CMS Panel Harness Pinout
CMS Panel Harness Pinout
The following attachment (Attachment A) shows the harness pinout from the 70 pin
Application port connector on the Engine Simulator Panel to the 40 pin connector on
the CMS Display unit. The wire length should be approximately 3 feet. This will
allow the CMS Display to be positioned beside the Engine Simulator Panel.
Attachment A
App Pin CMS Pin Wire ID Color
1-5 Not Used Not Used Not Used
6 5 644 OR
7 30 643 GN
8 32 426 BR
9 37 420 OR
10 8 290 BK
11 9 291 BK
12 36 412 BU
13 - 21 Not Used Not Used Not Used
22 23 893 GN
23-26 Not Used Not Used Not Used
27 3 410 WH
28 4 411 PK
29-35 Not Used Not Used Not Used
36 24 892 BR
37-40 Not Used Not Used Not Used
41 12,15,16,18 403,443,442,447 GN,Y,GY,PK
42-44 Not Used Not Used Not Used
45 1,7 113,A401 OR
46 Not Used Not Used Not Used
47 2,25,27,28,29 201 BK
48-70 Not Used Not Used Not Used

The Caterpillar Engine Simulator D11N-10

 D11N Application
CMS Panel Harness Pinout
.

1 2 3 4 5 6 7 8 9 10

15 16
11 20

21 30
25 26

31 32 33 34 35 36 37 38 39 40

CMS Deutsch 40 Pin Connector

2 3 4 5 6 7 8 9 10 11 12 13
1 14
15 22 28
29 42
43 49 56
57 70
58 59 60 61 62 63 64 65 66 67 68 69

Application Port Deutsch 70 Pin Connector

Add Jumper to D11N ECM Harness

Add jumper to D11N ECM Harness part number (124-2451) at panel connector A.
Connect a jumper wire from Panel connector A pin 32 to pin 52. This jumper is nec-
essary to operate the CMS Monitoring System for the D11N application. Do not add
jumper to the ECM side of the harness.

The Caterpillar Engine Simulator D11N-11

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 Panel Set to local voltage
Voltage Selector (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 Atmospheric

Pressure Sensor Pressure
Sensor

Turbo Inlet Left Oil Pressure

Pressure Sensor Sensor

Crankcase
Pressure
Turbo Inlet Right Sensor
Pressure Sensor

Instrument Panel

Tachometer Ether Ignition

Manual Load

Not Used Throttle Crank

The Caterpillar Engine Simulator 3500B-3

 3500B Application
Application Information
Electrical Control System Diagram
Electronic Control
Module

Electronic Unit Disconnect Seitch

Injectors (8)
-
24V
+
P26
TPC Service Probe Access Vehicle
Oil Pressure Sensor (filtred) P22/J22 Ground Bolt
Main Power
Relay
Turbo Outlet Pressure Sensor P23/J23
Engine Control
15A Breaker Keyswitch
Right Turbo Inlet Pressure Sensor P25/J25 Engine
Harness

Left Turbo Inlet Pressure Sensor P28/J28

CAT Data Link
Speed/Timing Sensor P20/J20 Service Tool

Crankcase Pressure Sensor P29/J29 Vehicle

Harness
Ether Manual Switch
Left Turbine Inlet Exhaust
Temperature Sensor J30/P30

Right Turbine Inlet Exhaust

Temperature Sensor J31/P31 Ether Start Ether Hold
Relay Relay
Jacket-Water Temperature Sensor J21/P21 J37/P37
J36/P21

Atmospheric Pressure Sensor 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 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
56.280 102 815 0.14
[PSI] [°F] [°F] [PSI] Clear Override

Oil Jacket Exhaust Crankcase

Pressure Water Temp. Pressure
[absolute] Temp [R&L] [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 Ether Solenoid System

Relays Control
1
Ether
Start Manual
Sensor
0 Override
Ether
Hold 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, fol-
low 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 (-40°F). 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 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 Technician Status
F ile Diagnostics I nformation Service Utilities Data Link Se t tings Help

Status Active Codes Logged Codes Configuration Exit

Engine: 3508B Training Aid

High Engine
Coolant Temp
3508B Training Aid Group 1
Engine: 3508B Training Aid
13 PSI Boost Pressure
1937 RPM Desired Engine Speed
1937 RPM Engine Speed
214 FRC Fuel Limit
93 Fuel Position
112 Rated Fuel Limit
100% Throttle Position
77 Percent Load

Groups . . . M ore Zoom In H o ld 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 Utilities Data Link Se t tings Help
Status Active Codes Logged Codes Configuration Exit

Desctiption State Trip Point Delay Time

Low System Voltage
Warn Operator On 24 Volts 5 Sec
Low Engine Oil Pressure
Warn Operator On None 1 Sec
Engine Derate On None 1 Sec
Engine Shutdown On None 1 Sec
High Engine Coolant Temperature
Warn Operator On 216 Det F 5 Sec
Engine Derate On 221 Deg F 5 Sec
Engine Shutdown On 225 Deg F 5 Sec
Low Engine Coolant Temperature
Warn Operator On 167 Deg F 5 Sec
Engine Overspeed
Warn Operator On 2100 RPM 0 Sec
Engine Shutdown On 2200 RPM 0 Sec
High Air Filter Restriction Pressure
Warn Operator On 28” H20 5 Sec
Engine Derate On 28” H20 5 Sec
Change Print
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 warn-
ings, 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