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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.
2006 Caterpillar
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SECTION CONTENTS
General Data ....................... 2
Aftercooler/Oil Cooler
Cooling
2006 Caterpillar
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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
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
2006 Caterpillar
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G3508
G3512
G3516
G3520B
45 (113)
45 (113)
45 (113)
45 (113)
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)
41/45 (106/113)
41/45 (106/113)
41/45 (106/113)
41/45 (106/113)
62/66 (144/151)
62/66 (144/151)
62/66 (144/151)
62/66 (144/151)
69 (156)
69 (156)
69 (156)
69 (156)
53 (127)
53 (127)
53 (127)
53 (127)
125/380 (5/15)
125/380 (5/15)
125/380 (5/15)
125/380 (5/15)
2006 Caterpillar
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Page 3
G3508
G3512
G3516
G3520B
686 (27)
686 (27)
686 (27)
686 (27)
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)
Page 4
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Turbocharged Aftercooled
(TA) Models
152.4 mm (6 in)
203.0 mm (8 in)
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Page 5
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
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
19.05
0.75
38.1
1.5
25.4
1.0
19.05
0.75
76.2
3.0
25.4
1.0
22.86
0.90
76.2
3.0
44.45
1.75
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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Fuel System
System Description
Metric (English)
G3508
G3512
G3516
G3520B
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)
14 / 69 (2 / 10)
14 / 69 (2 / 10)
14 / 69 (2 / 10)
14 / 69 (2 / 10)
2006 Caterpillar
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Page 7
G3508
G3512
G3516
G3520B
275 (40)
275 (40)
275 (40)
275 (40)
100 (15)
100 (15)
100 (15)
100 (15)
138 (20)
138 (20)
138 (20)
138 (20)
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)
N/A
76 (20)
76 (20)
N/A
N/A
49 (13)
49 (13)
N/A
3.8 (1)
3.8 (1)
3.8 (1)
3.8 (1)
231 (61)
338 (89)
423 (112)
541 (143)
0.913 (0.0015)
0.913 (0.0015)
0.913 (0.0015)
0.913 (0.0015)
0.426 (0.0007)
0.426 (0.0007)
0.426 (0.0007)
0.426 (0.0007)
Page 8
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System Description
Metric (English)
G3508
G3512
G3516
G3520B
103 (15)
103 (15)
103 (15)
103 (15)
138 (20)
138 (20)
138 (20)
138 (20)
35 (5)
35 (5)
35 (5)
35 (5)
5 (1)
5 (1)
5 (1)
5 (1)
135 (36)
135 (36)
220 (58)
410 (108)
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Page 9
G3508
G3512
G3516
G3520B
105 (221)
105 (221)
105 (221)
105 (221)
109 (228)
109 (228)
109 (228)
109 (228)
113 (235)
113 (235)
113 (235)
113 (235)
5 (41)
5 (41)
5 (41)
5 (41)
114 (30)
148 (39)
205 (54)
270 (71)
System Description
Metric (English)
G3508
G3512
G3516
G3520B
13 (3.4)
15 (4)
16.5 (4.4)
17.5 (4.6)
Page 10
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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
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
2006 Caterpillar
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Page 11
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
G3508
G3512
G3516
2W-8772
2W-8772
169-3337
N/A
N/A
N/A
14.55
14.55
29.1
8N-7182
8N-7182
162-7460*
1.852
1.852
3.426
1.548
1.548
5.68
Damper Stiffness
MN-m/rad
0.367
0.169
0.4
508
565
875
Page 12
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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.
2006 Caterpillar
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Page 13
Starting Torque
System Description
Metric (English)
G3508
G3512
G3516
Breakaway Torque*
Nm (ft lb)
1016 (750)
1247 (920)
1545 (1140)
1085 (800)
1573 (1160)
1898 (1400)
854 (630)
1037 (765)
1288 (950)
Page 14
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Page 15
Page 16
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-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
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.
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.
2006 Caterpillar
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Page 17
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
N/A
0.56 (31.8)
0.56 (31.8)
N/A
N/A
N/A
N/A
N/A
Governor
Page 18
2006 Caterpillar
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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
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Page 19
LEBW5339-00
2006 Caterpillar
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