C-Series Mining Trucks

3500B Diesel Engines

T H E

D E F I N I T I O N

O F

V A L U E

777D

785C

789C

793C

Cat 3500B Engine Reliability

5130B

5230

992

D11R

a d v a n c e d
Todays mining and construction applications and productivity goals are more demanding than ever. Caterpillar trucks and machines equipped with Caterpillar engines provide not only unmatched reliability and performance, but also the advantage of being single source products designed and built from the start to work together. Improving on a Caterpillar engine isnt easy but neither is becoming a global leader. Caterpillar achieved and maintains this status by continually researching new technologies and developing innovative ways to deliver better engine performance and customer value.

How?
3516B

3512B

Increased reliability Enhanced protection and diagnostics Extended service intervals Lower fuel consumption
m o re p ro d u c t i v e

3508B

Lower cost per ton Higher horsepower Reduced emissions Improved response More precise control

Cat 3500B engines go beyond power; theyre setting new standards in performance, reliability, serviceability, and fuel economy.

The 3500B engines illustrate the Caterpillar commitment to continuous improvement with new advanced component designs.
1 Combustion system 2 Air system

A new two-piece piston design with an aluminum skirt and forged steel crown improves combustion of the air-fuel mixture in the cylinder. Its deep bowl crown reduces crevice volume, which boosts fuel efficiency and lowers emissions.

Higher efficiency turbochargers more precisely control airflow in the combustion chamber, allowing higher boost pressures at lower engine rpm. This improves engine response time.

s t r o n g e r
m o re d e p e n d a b l e
3 Rear gear train

Increased gear face width reduces stress under

4 Camshafts

increased pressures.

By increasing the diameter of the camshafts and strengthening the camshaft followers, push rods, and rocker arms, improved torsional stiffness and radial deflection have been achieved. Cam lobe profiles have also been adjusted to shorten the duration of fuel injection, ensuring injection occurs at the optimal moment.

Fuel system

The new fuel system design produces higher injection pressures over a shorter injection duration, which provides more efficient use of fuel and better engine response.

Air system

A redesign of the Separate Circuit AfterCooler (SCAC) provides enhanced serviceability through a reduction in the number of connections, hoses, and thermostats. And, by rerouting the hoses and relocating the surge tank, engine installation and removal are much simpler and faster.
5

iron

7 3 7 Cylinder block and heads

Stress-relieved, high tensile strength cast iron alloy resists twisting, flexing, and stress cracking even under the toughest operating conditions.

Advanced Electronics
Engine protection through electronics

optimal injection timing, amount, and duration by reading sensor feedback and air-fuel ratio maps. The electronic unit injectors in 3500B engines provide 10 to 20 percent higher injection pressure than on other 3500 engines. The rugged ECM is designed to withstand extremes in temperature, and is protected from electronic interference and vibration. Together, the ECM and electronic unit injectors provide unmatched operating precision and efficiency, and ensure peak engine performance at all times.
Diagnostics

code is generated and stored in memory. Active codes, indicating an immediate problem, alert operators to act to prevent unexpected downtime. Non-active codes, indicating an intermittent or already repaired problem, are logged and are useful for troubleshooting, locating intermittent problems, and maintenance. Diagnostic codes are easily accessed through the Cat Electronic Technician (ET) service tool or the Caterpillar Vital Information Management System (VIMS) display module. Many diagnostic parameters may also be retrieved and displayed including: boost pressure fuel flow rate engine rpm overspeed oil pressure overheating

Cat 3500B engines are protected by an advanced engine management system. The Caterpillar Electronic Control Module (ECM) is a computer which monitors engine functions and diagnoses potential problems, resulting in increased engine reliability and better performance. The ECM responds to the sensors after interfacing Caterpillar software and customer supplied performance parameters. Working in conjunction with the ECM are electronic unit injectors which, when signaled by the ECM, inject fuel. The ECM determines the

The ECM provides sophisticated diagnostic capabilities. When a problem is detected, a diagnostic

s m a r t e r
C ate r p i lla r E CM S e n s o r s
Coolant Temperature Sensor Boost Pressure Sensor Transmission Temperature Sensor Transmission Speed Sensor

Primary Speed Sensor

Oil Pressure Sensor

Coolant Level Sensor

Engine Management

Overspeed warning

Alarm and message

Acceleration delay on start-up

Allows engine lubrication, reducing wear

Elevated low idle in cold starts

Enables engine to reach operating temperature

Cold mode start capability

Retards timing to reduce peak cylinder pressure

Air filter restriction

Automatic derate beyond indicated restriction point

more precise
Altitude compensation

Derates power by limiting fuel to prevent excessive exhaust gas temperatures and related damage
Fuel use record

Of cumulative consumption
Multi-point oil pressure sensing

Alarm sounds to prevent risk of piston damage

Ether aid

Injects at start-up when engine coolant temperature dictates the need

Starter protection

Uses engine speed and key position to control starter engagement, preventing damage

C-SERIES

MINING

TRUCKS

Caterpillar trucks and 3500B engines help meet the most demanding goals in mining and construction applications. Continuing innovations and development of high-performance components and sophisticated electronic controls mean increased productivity and decreased cost per ton. Maintaining superior performance requires superior support. And Caterpillar provides just that. The Caterpillar dealer network includes more than 1,200 outlets worldwide each fully staffed with trained technicians and equipped with the latest technology to keep our customers up and running. Each local Cat dealer also has instant satellite access to the most comprehensive parts location system in the world. Our 48-Hour Parts Policy delivers new or remanufactured Cat parts within two days 24 hours a day, 365 days a year right where they are needed. Superior products, superior support, superior results. Thats the Caterpillar commitment to getting the job done.

LEDH8400

1998 Caterpillar Inc.

Printed in U.S.A.