G3500LEBW5339-00

G3508 • G3512 G3516 • G3520

TECHNICAL INFORMATION G3500 GAS ENGINES

A P P L I C A T I O N A N D I N S T A L L A T I O N G U I D E

Contents

General Data.................................................................... 2

Combustion Air System..................................................... 3

Exhaust Gas System......................................................... 4

Loading on Turbocharger Exhaust, Maximum.................... 5

Vertical Exhaust ....................................................... 5

Horizontal Exhaust.................................................... 5

Fuel System .................................................................... 7

Lubricating Oil System ...................................................... 8

Cooling Water System .................................................... 10

Block Cooling............................................................. 10

Aftercooling / Oil Cooling............................................. 10

Torsional Vibration Analysis Information Data..................... 11

Engine Mass Elastic Data............................................. 11

Flywheel & Damper Information.................................... 12

Unbalanced Forces and Moments ................................. 13

Starting Torque.............................................................. 14

Vane Starter Performance Curve................................... 14

I-R Turbine Starter Performance Curves ......................... 15

TDI Starter Performance Curves ................................... 16

Electric Starting System .................................................. 17

Power Supply Requirements ............................................ 18

Reference Material.......................................................... 19

©2006 Caterpillar® All rights reserved.

Information contained in this publication may be considered confidential. Discretion is recommended when distributing. Materials and specifications are subject to change without notice.

CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow”, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Foreword This section of the Application and Installation Guide lists Technical

Information for Caterpillar® engines listed on the cover of this section. Additional engine systems, components and dynamics are addressed in other sections of this Application and Installation Guide.

Engine-specific information and data are available from a variety of sources. Refer to the Introduction section of this guide for additional references.

Systems and components described in this guide may not be available or applicable for every engine.

Application and Installation Guide Technical Data – G3500 Gas Engines

©2006 Caterpillar® All rights reserved. Page 1

Technical Information – 3500 Gas Engines This guide provides technical data for the Caterpillar 3500 gas engine

models offered to the Petroleum Market. At the time of publishing, this data is correct; updates will be included periodically and this section republished. Dealers may use the Technical Marketing Information system for the most current data.

SECTION CONTENTS General Data ....................... 2 Combustion Air System........ 3 • Loading on Turbocharger

Inlet, Maximum

Exhaust Gas System ............ 4 • Loading on Turbocharger

Outlet, Maximum

Fuel System ........................ 7 Lubricating Oil System.......... 8 Cooling Water System.........10 • Block Cooling

• Aftercooler/Oil Cooler Cooling

Torsional Vibration Analysis Information ........................11 • Engine Mass Elastic Data

• Flywheel and Damper Information

• Unbalanced Forces and Moments

Starting Air System.............14 • Vane Starter Performance

Curves

• I-R Turbine Starter Performance Curves

• TDI Starter Performance Curves

Electric Starting System ......17 Power Supply Requirements.18 Reference Material ..............19

Technical Data – G3500 Gas Engines Application and Installation Guide

©2006 Caterpillar® Page 2 All rights reserved.

General Data System Description Metric (English)

G3508 G3512 G3516 G3520B

Cylinder Bore mm (in) 170 (6.7) 170 (6.7) 170 (6.7) 170 (6.7)

Stroke mm (in) 190 (7.5) 190 (7.5) 190 (7.5) 190 (7.5)

Displacement/Cylinder L (in3) 4.3 (263) 4.3 (263) 4.3 (263) 4.3 (263)

Total Displacement L (in3) 34.5 (2105) 51.75 (3158) 69 (4211) 86.25 (5263)

Rated Speed rpm 1000 to 1800 1000 to 1800 1000 to 1800 1000 to 1800

Idle Speed, low rpm 700 700 700 700

Firing Order – CCW 1-2-7-3-4-5-6-8 1-12-9-4-5-8

-11-2-3-10-7-6

1-2-5-6-3-4-9-10

-15-16-11-12-13-14-7-8

1-2-11-12-3-4-15-16-7-8

-19-20-9-10-17-18-5-6-13-14

Firing Order – CW (optional by DTO only) 1-8-7-2-6-5-4-3

1-4-9-8-5-2

-11-10-3-6-7-12

1-6-5-4-3-10-9-16

-15-12-11-14-13-8-7-2 N/A

Wet weight kg (lb) 13,550 (6,146) 16,952 (7,689) 20,552 (9,322) 25,435 (11,537)

Dry weight kg (lb) 5,420 (11,950) 6,677 (14,720) 8,022 (17,670) 9,875 (21,770)

Crank Radius mm (in) 95 (3.74) 95 (3.74) 95 (3.74) 95 (3.74)

Connecting Rod Length mm (in) 380 (14.96) 380 (14.96) 380 (14.96) 380 (14.96)

Reciprocating Weight N (lb) 122.917 (27.633) 122.917 (27.633) 122.917 (27.633) 122.917 (27.633)



Combustion Air System System Description Metric (English)

G3508 G3512 G3516 G3520B

Air Temperature @ Air Cleaner (ambient), maximum °C (°F)

45 (113) 45 (113) 45 (113) 45 (113)

Inlet Manifold Air Temperature (32°C SCAC), G3500LE, nominal/shutdown °C (°F)

43/47 (110/117) 43/47 (110/117) 43/47 (110/117) 43/47 (110/117)


64/68 (147/154) 64/68 (147/154) 64/68 (147/154) 64/68 (147/154)


78/81 (172/178) 78/81 (172/178) 78/81 (172/178) 78/81 (172/178)

Inlet Manifold Air Temperature (32°C SCAC), G3500 Std, nominal/shutdown °C (°F)

41/45 (106/113) 41/45 (106/113) 41/45 (106/113) 41/45 (106/113)

Inlet Manifold Air Temperature (54°C SCAC), G3500 Std, nominal/shutdown °C (°F)

62/66 (144/151) 62/66 (144/151) 62/66 (144/151) 62/66 (144/151)

High Inlet Air Temperature (low load), G3500B, warning °C (°F)

69 (156) 69 (156) 69 (156) 69 (156)

High Inlet Air Temperature (high load), G3500B, warning °C (°F)

53 (127) 53 (127) 53 (127) 53 (127)

Air Inlet Restriction, new/maximum mm H2O (in H2O) 125/380 (5/15) 125/380 (5/15) 125/380 (5/15) 125/380 (5/15)



Exhaust Gas System System Description Metric (English) G3508 G3512 G3516 G3520B

Exhaust System Backpressure, maximum (naturally aspirated engine) mm H2O (in H2O)

686 (27) 686 (27) 686 (27) 686 (27)

Exhaust System Backpressure, maximum (turbocharged, aftercooled engine) mm H2O (in H2O)

305 (12) 305 (12) 305 (12) 305 (12)

Loading on Turbocharger Outlet

Maximum allowed vertical force N (lb)

178 (40) 178 (40) 178 (40) 178 (40)

Maximum allowed moment N•m (ft-lb) 120 (89.5) 120 (89.5) 120 (89.5) 120 (89.5)



Loading on Turbocharger Exhaust, Maximum Vertical Exhaust

C = Adapter Weight

I = 1/2 Bellows Weight

With Caterpillar Hardware: C = 28 N (6.4 lb)

I = 6 N (1.4 lb)

Sum of Vertical Forces Fv=C+I=28+6=34 N (7.8 lb)

Sum of Moments M=h1xC+h2xI=0x28+0x6=0 N•m (ft-lb)

Since Fv<111 N (25 lb) and M< 120 N•m (89.5 ft-lb), the exhaust system meets the load and moment requirements.

Horizontal Exhaust C = Adapter Weight

I = 1/2 Bellows Weight

J = Elbow Adapter

With Caterpillar Hardware: C = 28 N (6.4 lb)

I = 6 N (1.4 lb)

J = 47 N (10.7 lb)

h1 = 0

h2 = 100 mm (3.9 in)

h3 = 580 mm (22.8 in)

Sum of Vertical Forces Fv=C+I+J=28+6+47=81 N (18.5 lb)

Sum of Moments M=h1xC+h2xI+h3xJ=0x28+.100x6+.580x47=27.9 N•m (20.8 ft-lb)

Since Fv<111 N (25 lb) and M< 120 N•m (89.5 ft-lb), the exhaust system meets the load and moment requirements.

Exhaust Outlet Diameter Naturally Aspirated (NA)

Models Turbocharged Aftercooled

(TA) Models

152.4 mm (6 in) 203.0 mm (8 in)



Installation Limitations of Flexible Metal Hose-Type Exhaust Fittings

A Maximum Offset Between Flanges

B Maximum Compression

from Free Length

C Maximum Extension

from Free Length Hose Diameter

mm in mm in mm in

101.6 mm (4 in) 25.4 1.0 6.25 0.25 6.25 0.25

127 mm (5 in) 25.4 1.0 6.25 0.25 6.25 0.25

152.4 mm (6 in) 38.1 1.5 6.25 0.25 6.25 0.25

Installation Limitations of Bellows-Type Exhaust Fittings

A Maximum Offset Between Flanges

B Maximum Compression

from Free Length

C Maximum Extension

from Free Length Hose Diameter

mm in mm in mm in

203.2 mm (8 in) 19.05 0.75 38.1 1.5 25.4 1.0

304.8 mm (12 in) 19.05 0.75 38.1 1.5 25.4 1.0

355.6 mm (14 in) 19.05 0.75 76.2 3.0 25.4 1.0

457.2 mm (18 in) 22.86 0.90 76.2 3.0 44.45 1.75

Spring Rate for Flexible Fittings Bellows-Type

Spring Rate Diameter kN/m lb/in.

8 in. 29.7 170

12 in. 33.9 194

14 in. 68.5 391

18 in. 19.3 110



Fuel System System Description Metric (English) G3508 G3512 G3516 G3520B

Fuel Pressure Range minimum / maximum

Low Pressure Engines kPa (psi) 10 / 35 (1.5 / 5) 10 / 35 (1.5 / 5) 10 / 35 (1.5 / 5) 10 / 35 (1.5 / 5)

Low Pressure Engines, Landfill kPa (psi) 10 / 35 (1.5 / 5) 10 / 35 (1.5 / 5) 10 / 35 (1.5 / 5) 10 / 35 (1.5 / 5)

High Pressure, Low Emissions Engines 11:1 Compression Ratio kPa (psi)

207 / 276 (30 / 40) 207 / 276 (30 / 40) 207 / 276 (30 / 40) 207 / 276 (30 / 40)

High Pressure, Low Emissions Engines 8:1 Compression Ratio kPa (psi)

241 / 276 (35 / 40) 241 / 276 (35 / 40) 241 / 276 (35 / 40) 241 / 276 (35 / 40)

High Pressure Standard Turbocharged Aftercooled Engines kPa (psi)

172 / 207 (25 / 30) 172 / 207 (25 / 30) 172 / 207 (25 / 30) 172 / 207 (25 / 30)

Naturally Aspirated Engines kPa (psi) 14 / 69 (2 / 10) 14 / 69 (2 / 10) 14 / 69 (2 / 10) 14 / 69 (2 / 10)



Lubricating Oil System System Description Metric (English) G3508 G3512 G3516 G3520B

Minimum Oil Pressure, G3500, shutdown 1000 to 1800 rpm, High Idle kPa (psi)

275 (40) 275 (40) 275 (40) 275 (40)

Minimum Oil Pressure, G3500, shutdown 1000 to 1800 rpm, Low Idle kPa (psi)

100 (15) 100 (15) 100 (15) 100 (15)

Minimum Oil Pressure, G3500B/C/E, warning, 1200 rpm kPa (psi)

138 (20) 138 (20) 138 (20) 138 (20)

Minimum Oil Pressure, G3500B/C/E, shutdown, 1200 rpm kPa (psi)

103 (15) 103 (15) 103 (15) 103 (15)


224 (32.5) 224 (32.5) 224 (32.5) 224 (32.5)


190 (27.5) 190 (27.5) 190 (27.5) 190 (27.5)


310 (45) 310 (45) 310 (45) 310 (45)


276 (40) 276 (40) 276 (40) 276 (40)

High Engine Oil Temperature, warning

°C (°F) 102 (215) 102 (215) 102 (215) 102 (215)

High Engine Oil Temperature, shutdown

°C (°F) 104 (220) 104 (220) 104 (220) 104 (220)

Prelube Pump Capacity, intermittent (pneumatic) Lpm (gpm)

N/A 76 (20) 76 (20) N/A

Prelube Pump Capacity, intermittent (electric) Lpm (gpm)

N/A 49 (13) 49 (13) N/A

Prelube Pump Capacity, continuous (electric) Lpm (gpm)

3.8 (1) 3.8 (1) 3.8 (1) 3.8 (1)

Oil Sump Capacity L (gal)

231 (61) 338 (89) 423 (112) 541 (143)

BSOC @ 100% Load, typical naturally aspirated engine g/bkW-hr (lb/bhp-hr)

0.913 (0.0015) 0.913 (0.0015) 0.913 (0.0015) 0.913 (0.0015)

BSOC @ 100% Load, typical turbocharged aftercooled engine g/bkW-hr (lb/bhp-hr)

0.426 (0.0007) 0.426 (0.0007) 0.426 (0.0007) 0.426 (0.0007)



System Description Metric (English) G3508 G3512 G3516 G3520B

High Oil Filter Differential Pressure, warning kPa (psi)

103 (15) 103 (15) 103 (15) 103 (15)

High Oil Filter Differential Pressure, shutdown kPa (psi)

138 (20) 138 (20) 138 (20) 138 (20)

Low Oil Filter Differential Pressure, warning kPa (psi)

35 (5) 35 (5) 35 (5) 35 (5)

Low Oil Filter Differential Pressure, shutdown kPa (psi)

5 (1) 5 (1) 5 (1) 5 (1)

Main Oil Pump Flow Rate Lpm (gpm)

135 (36) 135 (36) 220 (58) 410 (108)



Cooling Water System

Block Cooling


High Engine Coolant Temperature, G3500, shutdown °C (°F)

105 (221) 105 (221) 105 (221) 105 (221)

High Engine Coolant Temperature, G3500B/C/E, warning °C (°F)

109 (228) 109 (228) 109 (228) 109 (228)

High Engine Coolant Temperature, G3500B/C/E, shutdown °C (°F)

113 (235) 113 (235) 113 (235) 113 (235)

Low Engine Coolant Temperature, G3500B/C/E, warning °C (°F)

5 (41) 5 (41) 5 (41) 5 (41)

Jacket Water Circuit Engine Volume L (gal) 114 (30) 148 (39) 205 (54) 270 (71)

Aftercooling / Oil Cooling


SCAC Circuit Engine Volume L (gal)

13 (3.4) 15 (4) 16.5 (4.4) 17.5 (4.6)



Torsional Vibration Analysis Information Data

Engine Mass Elastic Data

G3508 Engine Mass Elastic Data

Mass ID Inertia N-m-s2 Spring ID Stiffness

MN-m/rad Diameter

mm VD * FRT 0.4629 EK1 11.637 135

EJ1 1.860 EK2 6.779 135 EJ2 1.178 EK3 6.779 135 EJ3 1.178 EK4 6.779 135 EJ4 1.860 EK5 11.637 135

REAR 0.4629 FW *

* See separate table for damper and flywheel information



MN-m/rad Diameter

mm VD * FRT 0.4629 EK1 12.742 135 EJ1 1.688 EK2 8.626 135

EJ2 1.688 EK3 8.626 135 EJ3 1.691 EK4 8.626 135 EJ4 1.691 EK5 8.626 135 EJ5 1.688 EK6 8.626 135 EJ6 1.688 EK7 12.742 135

REAR 0.4629

FW * * See separate table for damper and flywheel information





MN-m/rad Diameter

mm VD * FRT 0.4629 EK1 12.742 135

EJ1 1.647 EK2 8.626 135 EJ2 1.731 EK3 8.626 135 EJ3 1.748 EK4 8.626 135 EJ4 1.756 EK5 8.626 135 EJ5 1.756 EK6 8.626 135 EJ6 1.748 EK7 8.626 135

EJ7 1.731 EK8 8.626 135 EJ8 1.647 EK9 12.742 135

REAR 0.4629 FW *

* See separate table for damper and flywheel information

Flywheel & Damper Information

System Description Metric (English) G3508 G3512 G3516

Engine Flywheel Group 2W-8772 2W-8772 169-3337

Engine Ring Gear Group N/A N/A N/A

Engine Flywheel & Ring Gear Inertia Kg-m2 14.55 14.55 29.1

Damper Group 8N-7182 8N-7182 162-7460*

Damper Housing Inertia Kg-m2 1.852 1.852 3.426

Damper Flywheel Inertia Kg-m2 1.548 1.548 5.68

Damper Stiffness MN-m/rad 0.367 0.169 0.4

Damper Absolute Damping N•m-sec/rad 508 565 875

* Data is for a single damper; G3516 Industrial is equipped with two.



Unbalanced Forces and Moments

Approximate Unbalanced Forces and Moments

Engine rpm * Force (lb)

Moment (lb-ft)

G3508 1000 721 1101 G3508 1200 1039 1586 G3508 1400 1414 2159

G3512 1000 889 1498 G3512 1200 1280 2156 G3512 1400 1742 2935 G3516 1000 1078 2049 G3516 1200 1552 2951 G3516 1400 2113 4016

* Caterpillar engines are balanced by design and do not exhibit or produce significant primary or secondary unbalanced forces or moments. These values represent Caterpillar estimates of the forces and moments due to manufacturing tolerances. An unbalanced assembly produces both primary and secondary forces and moments that are possible in both the horizontal and vertical directions. These values can be considered a 3 σ (sigma) limit; i.e. 99.9% of the engines will produce lower force and moment levels.



Starting Torque System Description Metric (English) G3508 G3512 G3516

Breakaway Torque* N•m (ft lb) 1016 (750) 1247 (920) 1545 (1140)

Cranking Torque** at 0°C (32°F) with SAE 30 Wt Oil N•m (ft-lbs) @ 100 or 150 rpm

1085 (800) 1573 (1160) 1898 (1400)

Cranking Torque** at 10°C (50°F) with SAE 30 Wt Oil N•m (ft-lbs) @ 100 or 150 rpm

854 (630) 1037 (765) 1288 (950)

Vane Starter Performance Curve

G3500 with One Vane Starter



I-R Turbine Starter Performance Curves

G3500 with One I-R ST950 Turbine Starter

G3500 with One I-R ST999 Turbine Starter



TDI Starter Performance Curves

G3512 & G3516 with TDI T121 V Air Starter (21 Nozzles, Compressed Air, 9.25:1 Ratio)

G3512 & G3516 with TDI T121 V Air Starter (21 Nozzles, Natural Gas, 9.25:1 Ratio)



Electric Starting System

Suggested Minimum Battery Cold Cranking Amps

24V – 32V Battery 1 Motor

30V – 32V Battery 2 Motors

-28°C (-20°F)

-18°C (0°F)

16°C (60°F)

-28°C (-20°F)

-18°C (0°F)

16°C (60°F)

G3508 1300 amps 1225 amps 925 amps

G3512 1300 amps 910 amps 725 amps

G3516 1300 amps 910 amps 725 amps

Electric Starter Breakaway* Performance

G3508, G3512 & G3516 Engines (183 flywheel teeth)

Starter Part Number

Volts at Starter Amps to Starter

Speed Starter/ Engine Cranking

Speed (rpm)

Potential Torque of Starter

(ft-lb)

Potential Torque on Flywheel

(ft-lb)

7C0527, 6V4246

(11 pinion teeth) 13 1400 0/0 92 1530

6V0927

(11 pinion teeth) 12.5 1400 0/0 100/1660 100/1660

* Breakaway torque is theoretically zero starter and zero engine rpm. However, the starter amperage limit is approximately 1400 amps.

Thus, the breakaway torque shown is reduced from actual to accommodate the amperage limit.

Electric Starter Cranking* Performance

G3508, G3512 & G3516 Engines (183 flywheel teeth)

Starter Part Number

Volts at Starter Amps to Starter Engine Cranking

Speed (rpm)

Potential Torque of Starter

(ft-lb)

Potential Torque on Flywheel

(ft-lb)

7C0527, 6V4246

(11 pinion teeth) 19 600 100 30 500

6V0927

(11 pinion teeth) 18.5 600 100 36 600

* Cranking torque is at 100 engine rpm. Cranking torque is very dependent on oil viscosity and temperature. When solving a crankcase

issue, increasing the temperature of the engine and the oil, plus lowering the viscosity of the oil, will dramatically improve cranking

performance.



Power Supply Requirements System Description Metric (English) G3508 G3512 G3516 G3520B

Jacket Water Heater, Optional kW (Btu/min)

6/12 (341.5/683.0) 6/12 (341.5/683.0) 6/9/12

(341.5/512.2/683.0) 9 (512.2)

Prelube Pump, continuous, 115/230 VAC 60 Hz or 50 Hz

7.9A@115 V /

3.9A@230 V

7.9A@115 V /

3.9A@230 V

7.9A@115 V /

3.9A@230 V

7.9A@115 V /

3.9A@230 V

Prelube Pump, intermittent, 24 VDC kW (Btu/min) N/A 0.56 (31.8) 0.56 (31.8) N/A

Status Control Panel N/A N/A N/A N/A

Governor Varies upon governor selection.



Reference Material The following information is

provided as additional reference to subjects discussed in this guide.

RENR2268 Systems Operation, Testing and Adjusting (G3500B Engines)

RENR2270 Troubleshooting (G3516B Engines)

RENR5927 Troubleshooting (G3520B Engines)

SEBU6711 Operation and Maintenance Manual (G3500 Engines)

LEBW5339-00 ©2006 Caterpillar® Printed in U.S.A. All rights reserved.

G3500LEBW5339-00

Documents

exhaust system

turbocharger

mm h2o

rights reserved

g3500 std

32c scac

54c scac

18 reference