G3500LEBW5339-00

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

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

•

•

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

Block Cooling Aftercooler/Oil Cooler Cooling

Torsional Vibration Analysis Information ........................11 •

•

Power Supply Requirements.18 Reference Material ..............19

Engine Mass Elastic Data


Page 1



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

13,550 (6,146)

16,952 (7,689)

20,552 (9,322)

25,435 (11,537)

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)

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

Wet weight kg (lb) Dry weight kg (lb) Crank Radius mm (in) Connecting Rod Length mm (in) Reciprocating Weight N (lb)

Page 2

122.917 (27.633) 122.917 (27.633)

N/A




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)


Page 3



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 N•m (ft-lb)

Page 4




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)


Page 5



Installation Limitations of Flexible Metal Hose-Type Exhaust Fittings

Hose Diameter

A

B

C

Maximum Offset

Maximum Compression

Maximum Extension

Between Flanges

from Free Length

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

B

C

Maximum Offset

Maximum Compression

Maximum Extension

Between Flanges

from Free Length

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




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)


Page 7



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)

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




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)


Page 9



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




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



Page 11



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


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

Damper Flywheel Inertia Kg-m2

1.548

1.548

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 N•m-sec/rad

3.426 5.68

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

Page 12




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.


Page 13



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

Page 14




I-R Turbine Starter Performance Curves G3500 with One I-R ST950 Turbine Starter

G3500 with One I-R ST999 Turbine Starter


Page 15



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




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)

G3512

1300 amps

910 amps

725 amps

G3516

1300 amps

910 amps

725 amps

G3508

-28°C (-20°F)

-18°C (0°F)

16°C (60°F)

1300 amps

1225 amps

925 amps

Electric Starter Breakaway* Performance G3508, G3512 & G3516 Engines (183 flywheel teeth) Speed Starter/ Starter Part Number

Volts at Starter

Amps to Starter

Engine Cranking

Potential Torque

Potential Torque

of Starter

on Flywheel

(ft-lb)

(ft-lb)

Speed (rpm)

7C0527, 6V4246 (11 pinion teeth) 6V0927 (11 pinion teeth)

13

1400

0/0

92

1530

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 r educed from actual to accommodate the amperage limit.

Electric Starter Cranking* Performance G3508, G3512 & G3516 Engines (183 flywheel teeth) Starter Part Number

Volts at Starter

7C0527, 6V4246 (11 pinion teeth) 6V0927 (11 pinion teeth)

Amps to Starter

Engine Cranking

Potential Torque

Potential Torque

Speed

of Starter

on Flywheel

(rpm)

(ft-lb)

(ft-lb)

19

600

100

30

500

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.


Page 17



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.




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)


Page 19

LEBW5339-00

©2006 Caterpillar®

Printed in U.S.A. All rights reserved.

G3500LEBW5339-00

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