APPLICATION
AND
INSTALLATION GUIDE
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
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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
Flywheel and Damper
Information
Unbalanced Forces and
Moments
Exhaust Gas System ............ 4
Loading on Turbocharger
Outlet, Maximum
Starting Air System.............14
Vane Starter Performance
Curves
I-R Turbine Starter
Performance Curves
Lubricating Oil System.......... 8
TDI Starter Performance
Curves
Cooling Water System.........10
Block Cooling
Electric Starting System ......17
Fuel System ........................ 7
Aftercooler/Oil Cooler
Cooling
Torsional Vibration Analysis
Information ........................11
Engine Mass Elastic Data
2006 Caterpillar
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Power Supply Requirements.18
Reference Material ..............19
Page 1
Technical Data G3500 Gas Engines
Application and Installation Guide
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)
34.5 (2105)
51.75 (3158)
69 (4211)
86.25 (5263)
1000 to 1800
1000 to 1800
1000 to 1800
1000 to 1800
700
700
700
700
1-12-9-4-5-8
1-2-5-6-3-4-9-10
1-2-11-12-3-4-15-16-7-8
-11-2-3-10-7-6
-15-16-11-12-13-14-7-8
-19-20-9-10-17-18-5-6-13-14
1-4-9-8-5-2
1-6-5-4-3-10-9-16
-11-10-3-6-7-12
-15-12-11-14-13-8-7-2
Total Displacement
L (in3)
Rated Speed
rpm
Idle Speed, low
rpm
Firing Order CCW
1-2-7-3-4-5-6-8
Firing Order CW
(optional by DTO only)
1-8-7-2-6-5-4-3
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)
95 (3.74)
95 (3.74)
95 (3.74)
95 (3.74)
380 (14.96)
380 (14.96)
380 (14.96)
380 (14.96)
122.917 (27.633)
122.917 (27.633)
Crank Radius
mm (in)
Connecting Rod Length
mm (in)
Reciprocating Weight
N (lb)
Page 2
122.917 (27.633) 122.917 (27.633)
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Application and Installation Guide
Technical Data G3500 Gas Engines
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 (32C SCAC),
G3500LE, nominal/shutdown
C (F)
43/47 (110/117)
43/47 (110/117)
43/47 (110/117)
43/47 (110/117)
Inlet Manifold Air Temperature (54C SCAC),
G3500LE, nominal/shutdown
C (F)
64/68 (147/154)
64/68 (147/154)
64/68 (147/154)
64/68 (147/154)
Inlet Manifold Air Temperature (70C SCAC),
G3500LE, nominal/shutdown
C (F)
78/81 (172/178)
78/81 (172/178)
78/81 (172/178)
78/81 (172/178)
Inlet Manifold Air Temperature (32C 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 (54C 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)
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Page 3
Technical Data G3500 Gas Engines
Application and Installation Guide
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)
178 (40)
178 (40)
178 (40)
178 (40)
120 (89.5)
120 (89.5)
120 (89.5)
120 (89.5)
Loading on Turbocharger Outlet
Maximum allowed vertical force
N (lb)
Maximum allowed moment
Nm (ft-lb)
Page 4
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Application and Installation Guide
Technical Data G3500 Gas Engines
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 Nm (ft-lb)
Since Fv<111 N (25 lb) and M< 120 Nm (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 Nm (20.8 ft-lb)
Since Fv<111 N (25 lb) and M< 120 Nm (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)
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Page 5
Technical Data G3500 Gas Engines
Application and Installation Guide
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)
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
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
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
Diameter
Page 6
Spring Rate
kN/m
lb/in.
8 in.
29.7
170
12 in.
33.9
194
14 in.
68.5
391
18 in.
19.3
110
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Application and Installation Guide
Technical Data G3500 Gas Engines
Fuel System
System Description
Metric (English)
G3508
G3512
G3516
G3520B
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)
14 / 69 (2 / 10)
14 / 69 (2 / 10)
14 / 69 (2 / 10)
14 / 69 (2 / 10)
Fuel Pressure Range
minimum / maximum
Naturally Aspirated Engines
kPa (psi)
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Page 7
Technical Data G3500 Gas Engines
Application and Installation Guide
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)
Minimum Oil Pressure, G3500B/C/E,
warning, 1500 rpm
kPa (psi)
224 (32.5)
224 (32.5)
224 (32.5)
224 (32.5)
Minimum Oil Pressure, G3500B/C/E,
shutdown, 1500 rpm
kPa (psi)
190 (27.5)
190 (27.5)
190 (27.5)
190 (27.5)
Minimum Oil Pressure, G3500B/C/E,
warning, 1800 rpm
kPa (psi)
310 (45)
310 (45)
310 (45)
310 (45)
Minimum Oil Pressure, G3500B/C/E,
shutdown, 1800 rpm
kPa (psi)
276 (40)
276 (40)
276 (40)
276 (40)
102 (215)
102 (215)
102 (215)
102 (215)
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)
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)
High Engine Oil Temperature, warning
C (F)
High Engine Oil Temperature, shutdown
C (F)
Oil Sump Capacity
L (gal)
Page 8
2006 Caterpillar
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Application and Installation Guide
Technical Data G3500 Gas Engines
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)
135 (36)
135 (36)
220 (58)
410 (108)
Main Oil Pump Flow Rate
Lpm (gpm)
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Page 9
Technical Data G3500 Gas Engines
Application and Installation Guide
Cooling Water System
Block Cooling
System Description
Metric (English)
G3508
G3512
G3516
G3520B
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)
114 (30)
148 (39)
205 (54)
270 (71)
System Description
Metric (English)
G3508
G3512
G3516
G3520B
SCAC Circuit Engine Volume
L (gal)
13 (3.4)
15 (4)
16.5 (4.4)
17.5 (4.6)
Jacket Water Circuit Engine Volume
L (gal)
Aftercooling / Oil Cooling
Page 10
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Application and Installation Guide
Technical Data G3500 Gas Engines
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
G3512 Engine Mass Elastic Data
Mass ID
Inertia
N-m-s2
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
*
* See separate table for damper and flywheel information
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Page 11
Technical Data G3500 Gas Engines
Application and Installation Guide
G3516 Engine Mass Elastic Data
Mass ID
Inertia
N-m-s2
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
*
* 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
14.55
14.55
29.1
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
508
565
875
Engine Flywheel & Ring Gear Inertia
Kg-m2
Damper Group
Damper Absolute Damping
Nm-sec/rad
* Data is for a single damper; G3516 Industrial is equipped with two.
Page 12
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Application and Installation Guide
Technical Data G3500 Gas Engines
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 (sigma)
limit; i.e. 99.9% of the engines will produce lower force and moment levels.
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Page 13
Technical Data G3500 Gas Engines
Application and Installation Guide
Starting Torque
System Description
Metric (English)
G3508
G3512
G3516
Breakaway Torque*
Nm (ft lb)
1016 (750)
1247 (920)
1545 (1140)
Cranking Torque** at 0C (32F)
with SAE 30 Wt Oil
Nm (ft-lbs) @ 100 or 150 rpm
1085 (800)
1573 (1160)
1898 (1400)
Cranking Torque** at 10C (50F)
with SAE 30 Wt Oil
Nm (ft-lbs) @ 100 or 150 rpm
854 (630)
1037 (765)
1288 (950)
Vane Starter Performance Curve
G3500 with One Vane Starter
Page 14
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Application and Installation Guide
Technical Data G3500 Gas Engines
I-R Turbine Starter Performance Curves
G3500 with One I-R ST950 Turbine Starter
G3500 with One I-R ST999 Turbine Starter
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Page 15
Technical Data G3500 Gas Engines
Application and Installation Guide
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)
Page 16
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Application and Installation Guide
Technical Data G3500 Gas Engines
Electric Starting System
Suggested Minimum Battery Cold Cranking Amps
24V 32V Battery
1 Motor
30V 32V Battery
2 Motors
-28C
(-20F)
-18C
(0F)
16C
(60F)
G3512
1300 amps
910 amps
725 amps
G3516
1300 amps
910 amps
725 amps
G3508
-28C
(-20F)
-18C
(0F)
16C
(60F)
1300 amps
1225 amps
925 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)
13
1400
0/0
92
1530
12.5
1400
0/0
100/1660
100/1660
7C0527, 6V4246
(11 pinion teeth)
6V0927
(11 pinion teeth)
Potential Torque
of Starter
(ft-lb)
Potential Torque
on Flywheel
(ft-lb)
* 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)
19
600
100
30
500
18.5
600
100
36
600
7C0527, 6V4246
(11 pinion teeth)
6V0927
(11 pinion teeth)
Potential Torque
of Starter
(ft-lb)
Potential Torque
on Flywheel
(ft-lb)
* 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.
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Page 17
Technical Data G3500 Gas Engines
Application and Installation Guide
Power Supply Requirements
System Description
Metric (English)
G3508
G3512
G3516
G3520B
6/12 (341.5/683.0)
6/12 (341.5/683.0)
6/9/12
(341.5/512.2/683.0)
9 (512.2)
7.9A@115 V /
7.9A@115 V /
7.9A@115 V /
7.9A@115 V /
3.9A@230 V
3.9A@230 V
3.9A@230 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
Jacket Water Heater, Optional
kW (Btu/min)
Prelube Pump, continuous, 115/230 VAC
60 Hz or 50 Hz
Governor
Page 18
Varies upon governor selection.
2006 Caterpillar
All rights reserved.
Application and Installation Guide
Technical Data G3500 Gas Engines
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)
2006 Caterpillar
All rights reserved.
Page 19
LEBW5339-00
2006 Caterpillar
Printed in U.S.A.
All rights reserved.
