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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
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

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)

2006 Caterpillar
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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)

2006 Caterpillar
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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

2006 Caterpillar
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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)

2006 Caterpillar
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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)

2006 Caterpillar
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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)

2006 Caterpillar
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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

2006 Caterpillar
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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

2006 Caterpillar
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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

2006 Caterpillar
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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

2006 Caterpillar
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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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All rights reserved.

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.

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