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

TECHNICAL INFORMATION

G3500 GAS ENGINES

G3508 • G3512

G3516 • G3520

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

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.

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.

©2006 Caterpillar®

All rights reserved.

Application and Installation Guide Technical Data – G3500 Gas Engines

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

• Flywheel and Damper

Information

• Unbalanced Forces and

Moments

Starting Air System.............14

• Vane Starter Performance

Curves

• I-R Turbine Starter

Performance Curves

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

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

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

• Block Cooling

• Aftercooler/Oil Cooler

Cooling

• TDI Starter Performance

Curves

Electric Starting System ......17

Power Supply Requirements.18

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

Torsional Vibration Analysis

Information ........................11

• Engine Mass Elastic Data


All rights reserved. Page 1

Technical Data – G3500 Gas Engines Application and Installation Guide

General Data

System Description

Metric (English)

Cylinder Bore mm (in)

Stroke mm (in)

Displacement/Cylinder

L (in 3 )

Total Displacement

L (in 3 )

Rated Speed rpm

Idle Speed, low rpm

Firing Order – CCW

G3508

170 (6.7)

190 (7.5)

4.3 (263)

34.5 (2105)

1000 to 1800

G3512

170 (6.7)

190 (7.5)

4.3 (263)

51.75 (3158)

1000 to 1800

G3516

170 (6.7)

190 (7.5)

4.3 (263)

69 (4211)

1000 to 1800

G3520B

170 (6.7)

190 (7.5)

4.3 (263)

86.25 (5263)

1000 to 1800

700 700 700

1-2-7-3-4-5-6-8

1-8-7-2-6-5-4-3

1-12-9-4-5-8

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

1-4-9-8-5-2

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

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

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

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

-15-12-11-14-13-8-7-2

700

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

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

N/A

Firing Order – CW

(optional by DTO only)

Wet weight kg (lb)

Dry weight kg (lb)

Crank Radius mm (in)

Connecting Rod Length mm (in)

Reciprocating Weight

N (lb)

13,550 (6,146) 16,952 (7,689)

5,420 (11,950) 6,677 (14,720)

95 (3.74)

380 (14.96)

95 (3.74)

380 (14.96)

122.917 (27.633) 122.917 (27.633)

20,552 (9,322)

8,022 (17,670)

95 (3.74)

380 (14.96)

122.917 (27.633)

25,435 (11,537)

9,875 (21,770)

95 (3.74)

380 (14.96)

122.917 (27.633)

Page 2 All rights reserved.


Combustion Air System



Air Temperature @ Air Cleaner

(ambient), maximum

°C (°F)

Inlet Manifold Air Temperature (32°C SCAC),

G3500LE, nominal/shutdown

°C (°F)



°C (°F)



°C (°F)


G3500 Std, nominal/shutdown

°C (°F)


G3500 Std, nominal/shutdown

°C (°F)

High Inlet Air Temperature (low load),

G3500B, warning

°C (°F)

High Inlet Air Temperature (high load),

G3500B, warning

°C (°F)

Air Inlet Restriction, new/maximum mm H

2

O (in H

2

O)

G3508

45 (113)

43/47 (110/117)

64/68 (147/154)

78/81 (172/178)

41/45 (106/113)

62/66 (144/151)

69 (156)

53 (127)

125/380 (5/15)

G3512

45 (113)

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

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

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

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

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

69 (156)

53 (127)

125/380 (5/15)

G3516

45 (113)

69 (156)

53 (127)

125/380 (5/15)

G3520B

45 (113)

69 (156)

53 (127)

125/380 (5/15)



Technical Data – G3500 Gas Engines

Exhaust Gas System



Exhaust System Backpressure, maximum

(naturally aspirated engine) mm H

2

O (in H

2

O)

Exhaust System Backpressure, maximum

(turbocharged, aftercooled engine) mm H

2

O (in H

2

O)

Loading on Turbocharger Outlet

Maximum allowed vertical force

N (lb)

Maximum allowed moment

N•m (ft-lb)

G3508

686 (27)

305 (12)

178 (40)

120 (89.5)

G3512

686 (27)

305 (12)

178 (40)

120 (89.5)

Application and Installation Guide

G3516

686 (27)

305 (12)

178 (40)

120 (89.5)

G3520B

686 (27)

305 (12)

178 (40)

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

F v

=C+I=28+6=34 N (7.8 lb)

Sum of Moments

M=h

1 xC+h

2 xI=0x28+0x6=0 N•m (ft-lb)

Since F v

<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) h

1

= 0 h

2

= 100 mm (3.9 in) h

3

= 580 mm (22.8 in)

Sum of Vertical Forces

F v

=C+I+J=28+6+47=81 N (18.5 lb)

Sum of Moments

M=h

1 xC+h

2 xI+h

3 xJ=0x28+.100x6+.580x47=27.9 N•m (20.8 ft-lb)

Since F v

<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

Hose Diameter

A

Maximum Offset

Between Flanges

B

Maximum Compression from Free Length

C

Maximum Extension from Free Length 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)

Hose Diameter

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 mm in mm in mm in

203.2 mm (8 in)

304.8 mm (12 in)

355.6 mm (14 in) 19.05

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

Spring Rate for Flexible Fittings

Bellows-Type

Diameter

8 in. kN/m

Spring Rate lb/in.

29.7 170

12 in. 33.9 194

14 in.

18 in.

68.5

19.3

391

110



Fuel System



Fuel Pressure Range minimum / maximum

Low Pressure Engines kPa (psi)

Low Pressure Engines, Landfill kPa (psi)

High Pressure, Low Emissions Engines

11:1 Compression Ratio kPa (psi)

High Pressure, Low Emissions Engines

8:1 Compression Ratio kPa (psi)

High Pressure Standard Turbocharged

Aftercooled Engines kPa (psi)

Naturally Aspirated Engines kPa (psi)

G3508

10 / 35 (1.5 / 5)

10 / 35 (1.5 / 5)

10 / 35 (1.5 / 5)

10 / 35 (1.5 / 5)

10 / 35 (1.5 / 5)

10 / 35 (1.5 / 5)

10 / 35 (1.5 / 5)

10 / 35 (1.5 / 5)

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

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

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

14 / 69 (2 / 10)

G3512

14 / 69 (2 / 10)

G3516

14 / 69 (2 / 10)

G3520B

14 / 69 (2 / 10)




Lubricating Oil System



Minimum Oil Pressure, G3500, shutdown

1000 to 1800 rpm, High Idle kPa (psi)

Minimum Oil Pressure, G3500, shutdown

1000 to 1800 rpm, Low Idle kPa (psi)

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

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





High Engine Oil Temperature, warning

°C (°F)

High Engine Oil Temperature, shutdown

°C (°F)

Prelube Pump Capacity, intermittent

(pneumatic)

Lpm (gpm)

Prelube Pump Capacity, intermittent

(electric)

Lpm (gpm)

Prelube Pump Capacity, continuous

(electric)

Lpm (gpm)

Oil Sump Capacity

L (gal)

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

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

G3508

275 (40)

100 (15)

138 (20)

103 (15)

224 (32.5)

190 (27.5)

310 (45)

276 (40)

102 (215)

104 (220)

N/A

N/A

3.8 (1)

231 (61)

0.913 (0.0015)

0.426 (0.0007)

G3512

275 (40)

100 (15)

138 (20)

103 (15)

224 (32.5)

190 (27.5)

310 (45)

276 (40)

102 (215)

104 (220)

76 (20)

49 (13)

G3516

275 (40)

100 (15)

138 (20)

103 (15)

224 (32.5)

190 (27.5)

310 (45)

276 (40)

102 (215)

104 (220)

76 (20)

49 (13)

G3520B

275 (40)

100 (15)

138 (20)

103 (15)

224 (32.5)

190 (27.5)

310 (45)

276 (40)

102 (215)

104 (220)

N/A

N/A

3.8 (1)

338 (89)

0.913 (0.0015)

3.8 (1)

423 (112)

0.913 (0.0015)

3.8 (1)

541 (143)

0.913 (0.0015)

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





High Oil Filter Differential Pressure, warning kPa (psi)

High Oil Filter Differential Pressure, shutdown kPa (psi)

Low Oil Filter Differential Pressure, warning kPa (psi)

Low Oil Filter Differential Pressure, shutdown kPa (psi)

Main Oil Pump Flow Rate

Lpm (gpm)

G3508

103 (15)

138 (20)

35 (5)

5 (1)

135 (36)


G3512

103 (15)

138 (20)

35 (5)

5 (1)

135 (36)

G3516

103 (15)

138 (20)

35 (5)

5 (1)

220 (58)

G3520B

103 (15)

138 (20)

35 (5)

5 (1)

410 (108)




Cooling Water System

Block Cooling



High Engine Coolant Temperature,

G3500, shutdown

°C (°F)


G3500B/C/E, warning

°C (°F)


G3500B/C/E, shutdown

°C (°F)

Low Engine Coolant Temperature,

G3500B/C/E, warning

°C (°F)

Jacket Water Circuit Engine Volume

L (gal)

G3508

105 (221)

109 (228)

113 (235)

5 (41)

114 (30)

Aftercooling / Oil Cooling



SCAC Circuit Engine Volume

L (gal)

G3508

13 (3.4)

G3512

105 (221)

109 (228)

113 (235)

5 (41)

148 (39)

G3512

15 (4)


G3516

105 (221)

109 (228)

113 (235)

5 (41)

205 (54)

G3516

16.5 (4.4)

G3520B

105 (221)

109 (228)

113 (235)

5 (41)

270 (71)

G3520B

17.5 (4.6)



Torsional Vibration Analysis Information Data

Engine Mass Elastic Data

G3508 Engine Mass Elastic Data

Mass ID

Inertia

N-m-s 2

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


Mass ID

Inertia

N-m-s 2

Spring ID

Stiffness

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 *






Mass ID

Inertia

N-m-s 2

Spring ID

Stiffness

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 *


Flywheel & Damper Information



Engine Flywheel Group

G3508 G3512 G3516

2W-8772 2W-8772 169-3337

Engine Ring Gear Group

N/A N/A N/A

Engine Flywheel & Ring Gear Inertia

Kg-m 2

Damper Group

14.55 14.55 29.1

8N-7182 8N-7182 162-7460*

Damper Housing Inertia

Kg-m 2

Damper Flywheel Inertia

Kg-m 2

Damper Stiffness

MN-m/rad

Damper Absolute Damping

N•m-sec/rad

1.852 1.852 3.426

1.548 1.548 5.68

0.367 0.169 0.4

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

G3508 rpm

* Force

(lb)

Moment

(lb-ft)

1000 721 1101

G3512 1000 889 1498

* 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



Breakaway Torque*

N•m (ft lb)

Cranking Torque** at 0°C (32°F) with SAE 30 Wt Oil

N•m (ft-lbs) @ 100 or 150 rpm

Cranking Torque** at 10°C (50°F) with SAE 30 Wt Oil

N•m (ft-lbs) @ 100 or 150 rpm

G3508

1016 (750)

1085 (800)

854 (630)

G3512

1247 (920)

1573 (1160)

1037 (765)

Vane Starter Performance Curve

G3500 with One Vane Starter

G3516

1545 (1140)

1898 (1400)

1288 (950)



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

G3508

G3512

G3516

Suggested Minimum Battery Cold Cranking Amps

-28°C

(-20°F)

24V – 32V Battery

1 Motor

-18°C

(0°F)

16°C

(60°F)

-28°C

(-20°F)

30V – 32V Battery

2 Motors

-18°C

(0°F)

16°C

(60°F)

1300 amps 1225 amps 925 amps

1300 amps

1300 amps

910 amps

910 amps

725 amps

725 amps

Starter Part

Number

Electric Starter Breakaway* Performance

G3508, G3512 & G3516 Engines (183 flywheel teeth)

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)

6V0927

(11 pinion teeth)

13 1400 0/0 92 1530

* 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



Jacket Water Heater, Optional kW (Btu/min)

Prelube Pump, continuous, 115/230 VAC

60 Hz or 50 Hz

G3508

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

7.9A@115 V /

3.9A@230 V

G3512

7.9A@115 V /

3.9A@230 V

Prelube Pump, intermittent, 24 VDC kW (Btu/min)

N/A 0.56 (31.8)

Governor

G3516

6/9/12

(341.5/512.2/683.0)

7.9A@115 V /

3.9A@230 V

0.56 (31.8)

G3520B

9 (512.2)

7.9A@115 V /

3.9A@230 V

N/A

N/A N/A N/A N/A

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.

Table of Contents

TECHNICAL INFORMATION

G3500 GAS ENGINES

Contents

Foreword

Technical Information – 3500 Gas Engines

General Data

Combustion Air System

Exhaust Gas System

Fuel System

Lubricating Oil System

Cooling Water System

Torsional Vibration Analysis Information Data

Starting Torque

Electric Starting System

Power Supply Requirements

Reference Material

Related documents

Products

Support