3500B Engines-Application & Installation Guide PDF

3500B Engines
Application and
Installation Guide
4-97
Table of Contents
General Information...................................................................................3
General Dimension Drawings..................................................................4
Support Literature......................................................................................6
Electrical ........................................................................................................7
Programmable Options ...........................................................................54
Monitoring System Features and Capabilities .................................60
Programmable Relay Control Module ................................................78
Customer Communications Module ....................................................82
Cooling System...........................................................................................86
Radiator Sizing .......................................................................................87
Cooling Schematic .................................................................................90
Aftercooler Circuit Volumes................................................................92
Heat Exchanger Performance ............................................................94
Aftercooler................................................................................................99
Emissions _ ISO 8179-1...........................................................................106
3508B Performance.................................................................................107
3512B Performance.................................................................................127
3516B Performance.................................................................................147
Partial List of Suppliers of Marine Controls..................................170
This data contained herewith can be used for preliminary design.

Before design is finalized, all data should be confirmed by your Caterpillar ® dealer.
Materials and specifications are subject to change without notice.
1
General Information Monitoring Differences
between the 3500B and Previous
The 3500B Family of Caterpillar Engines were 3500 Engines
designed primarily to meet the emissions
• Histograms
standards of the next century. Their cleanliness is
enhanced by significantly higher ratings, better • Logged engine events
fuel efficiency, state of the art monitoring and • Programmable alarms and controls
engine protection capability. There are several (programmable relay module)
differences between the 3500B and their 3500 • Monitoring of engines through computer and
predecessors. telephone networks (customer communications
module)
Mechanical Differences
between the 3500B and Previous Similarities
3500 Engines
• Electronic control module instead of mechanical 3500 Engines
governor
• Envelope _ The basic engine is physically nearly
• Electric unit injectors with higher injection the same as the previous engines. Mounting is
pressures the same.
• No Mechanical Rack Control linkage in fuel • Connection to Driven Equipment _ the bolt
system circles, flywheel sizes, auxiliary drives...are all
• Larger (98 mm) cam bore in cylinder block the same
• Heavier rear gear train • Jacket Water, Oil and Fuel Connections are in
• Separate circuit aftercooling (with temperature the same location and are the same size as
control in some applications) analogous prior 3500 Engines.
• The engine is self-diagnosing • Almost all the attachments are readily usable on
prior and B engines.
• Two piece, steel crown, articulated, piston with
aluminum skirt
• Larger (19 in. long) air cleaners on 16 cylinder
B engines (14 in. on 3512 and 3508).
• Enhanced aftercooler serviceability
Performance Differences
3500 Engines
• Superior emissions
• Better fuel consumption
• Higher power ratings
• Uses lube oil designated CF-4 or CG-4
• Optimizes injection timing, throughout the
operating range
• Protective power reductions when dangerous
conditions exist; overheating of exhaust or
jacket water, fouled air filters, etc. ...
• Programmable, automatic cool-down
3
3500B Marine Engine General Dimension Drawings
(because of the volume and number of the new drawings, access the actual
drawings via the RASTAR or AutoCAD Systems)
General
Dimension
Drawing
Market Number
3516B Package Gen Set with Low Fuel Consumption 123-7396
3516B Package Gen Set with Low NOx Emissions 123-3180
3508 Optional Generators 125-7852
3508 Prime and Continuous with FC60 Radiator 106-2090
3508 Prime with FC50 Radiator and 125-3444

680 Frame Generator
3508 Prime and Continuos with 690 Frame 125-3445

2 Bearing Generator
3508 Standby w/FC60 and 72 Radiator with 690 125-3446

Single Bearing Generator
3512 Prime, Standby & Continuos with all 108-2091

Radiators and Generators
3516 Prime, Standby with 46CV Radiator and 105-2900

820 2 Bearing Generators with 2 Turbos
3516 Prime, Continuos & Standby with 46CV Rad and 125-0709
and 820 Single Bearing Generators with Quad Turbos
3516 Prime, Continuos & Standby w/FC72 Rad and 4P-3853

820 Single Bearing Generators with Quad Turbos
3516 Prime, Continuos FC60 & 72 Radiators and 9Y-4535

800 & 820 Single Bearing Generators with 2 Turbos
4
3500B Marine Engine General Dimension Drawings (continued)
(because of the volume and number of the new drawings, access the actual
drawings via the RASTAR or AutoCAD Systems)
General
Dimension
Drawing
Market Number
3516 Prime, Continuos, and Standby with 46CV Rad and 9Y-5402
820 Single Bearing Generator Twin Turbo
3516 Prime Power with Kato Generator 104-8652
3516 Standby Power with Kato Generator 100-8748
3516 Prime, Continuos & Standby FC72 Radiator 125-0708

with 696 Frame Generator Quad Turbo
3512B Package Generator Set - Standby 126-5090
3512B Package Generator Set - Prime 126-5091
3508B Package Generator Set - Standby 126-5088
3508B Package Generator Set - Prime 126-5089
3516B SCAC Marine Engine - Heavy Weight 120-4499
3512B Marine Engine - Heavy Weight 115-3615
3508B Marine Engine - Heavy Weight 110-2754
3516B SCAC Marine Engine - Light Weight 125-6281
3512B Marine Engine - Light Weight 115-3610
3508B Marine Engine - Light Weight 116-8022
3516B SCAC Marine Auxiliary 125-6280
3512B Marine Auxiliary 125-6279
3508B Marine Auxiliary 125-6278
5
3500B Marine Engine
Support Literature
Description Form
Number
Troubleshooting - 3500B EPG Diesel Engines SENR1003
Troubleshooting - 3500B EPG with EMCP-II SENR1004
Troubleshooting - 3500B EPG with Switchgear Conversion SENR1005
Specifications - 3500B EPG&Marine Engines SENR6562
3500B Marine Engine Systems Operation, Testing and Adjusting SENR6563
Disassembly & Assembly Manual - Marine and Gen Set SENR6564
EPG Load Sensor and Load Sharing Module SENR6565
Service Manual - 3500B Electronic Instrument Panel SENR6587
Programmable Relay Control Panel (PRCM) SENR6588
Service Manual for SR4B Generator SENR8395
3500B Operation and Maintenance - (EPG) SEBU6916
Operation and Maintenance (Marine Engines) SEBU6917
Operation and Maintenance - (SR4B) SEBU6918
Troubleshooting - 3500 Marine Diesel Engines SENR1008
Troubleshooting - 3500 Marine Propulsion (Dual ECM) SENR1009
Troubleshooting - 3500 Marine Auxiliary SENR1010
Customer Communications Module for (EMCPII) Owners Manual SEBU6874
Digital Voltage Regulator SENR5833
Woodward Load Sharing Governor Module SENR6501
DeNox Service Manual SENR1007
Owners Manual - Customer Communications Module (CCM) for use with EMCP-II SEBU6874
6
3500B Marine Electrical
Index
Parts Required ..............................................................8 Throttle and Engine Synchronization System for
Triple Engine control by CENTER Throttle ............29
Service Tools ..................................................................8
Throttle and Engine Synchronization System for
3500B Marine Propulsion Triple Engine control by PORT Throttle ..................31
Electronic Control System ...........................................9
Throttle Position Sensor Calibration ........................32
3500B Marine Generator Set
Electronic Control System .........................................10 Connecting Backup Throttle Position Sensor for
Single Engine Installation .........................................33
Power Supply Requirements .....................................11
Connecting Premium Pilot House Panel
Recommended Wire Size - Customer supplied.........11 w/Switches to EIP .......................................................34
Harness Wire Identification ......................................11 Connecting Basic Pilot House Panel

w/Switches ...................................................................35
Electrical System Grounding Requirements ...........12
Connecting Basic Pilot House Panel
Connecting Programmable Relay Control Module w/o Switches to EIP ....................................................36
(PRCM) to EIP ............................................................13
Using CCM as a CAT Data Link
Connecting Relay & Circuit Breaker Signal Booster .............................................................37
inside EIP for PRCM power control ..........................14
Connecting a Marine Gear Oil Pressure Sensor
Connecting Programmable Relay Control Module to the EIP .....................................................................39
(PRCM) to one or two Relay Driver Module(s) ........15
Connecting a Marine Gear Oil Temperature
Connecting Relay Driver Module Sensor to the EIP ........................................................40
to Relay Board Assembly ...........................................16
Connecting a Danfoss (or similar) Shutdown Switch
Connecting to Relay Contacts to the EIP for use with PHP with Start/Stop &
on Relay Board Assembly ..........................................17 E-Stop Switches ..........................................................41
Connecting Customer Communication
Module (CCM) to EIP .......................................18 & 19 Generator Set Only Applications
Connecting a Woodward Loadshare Module
Connecting Customer Communication to the EIP .....................................................................42
Module (CCM) to a MODEM .....................................20
Connecting a Speed Adjust Potentiometer
Connecting Customer Communication Module to the EIP .....................................................................43
(CCM) to a Personal Computer .................................21
Connecting an Air Temperature Sensor
Connecting Customer Communication Module to the EIP .....................................................................44
(CCM) to a Satellite Receiver/Transmitter ..............22
Connecting an Engine Oil Temperature Sender
Connecting a Remote Start/Stop Switch to the EIP .....................................................................45
to the EIP .....................................................................23
Connecting a Battery Charger Fault Switch
Connecting a Remote E-Stop Switch to the EIP......................................................................46
to the EIP .....................................................................24
Adding Circuits inside EIP for CCM
Connecting a Coolant Level Sensor to the EIP .......25 Power Control...............................................................47
Connecting a Fuel Level Switch to the EIP .............26 Connecting Customer Communication Module
(CCM) to an Engine Vision Display...........................48
Wiring Diagrams / Harnesses ....................................49

Marine Propulsion Only Applications
Connecting a 4-20 mA Converter for Throttle Considerations in Providing Power to the
Input to Engine Electronic Control System .............27 3500B Engines ............................................................50
Throttle and Engine Synchronization System for Tools for 3500B Engines -
Dual Engine control ....................................................28 Electronic and Wiring..................................................51
7
Parts Required Electronic Service Tools
The Following chart is a reference for ordering the The installation requires the use ET (Electronic
TOTAL parts required. Refer to the individual charts Technician) Service Tools.
for the specific parts (and quantity) required for that
particular parts installation.
Items and quantity will vary according to the
installation options chosen.
1. Contact the PC hotline at 1-800-THE-PCDR (843-7237)

for more information.
2. Refer to Tool Operating Manual SEHS9264, Installation and
use of the 7X-1701 Communication Adapter Tool.
3. This is a subscription, since it is anticipated that it will be
changing at regular intervals
8
3500B Marine Propulsion
Electronic Control System
9
3500B Marine Generator Set
Electronic Control System
10
Power Supply Requirements Harness Wire Identification
The Following chart is a reference for specifying The present type of wire identification, used on
power supply current requirements of each Caterpillar 3500B Family of Engines, uses only
subsystem component. Adding up the supply eleven solid colors.
requirements of each component will yield the
TOTAL supply requirement for a given system.
Items and quantity will vary according to the
installation options chosen.
In addition to only eleven basic colors of wire, a

circuit number is printed on each wire. The circuit
number is printed approximately every 25 mm for
the length of the entire wire.
For example: A color code of “F702-GN” on the
Recommended Wire Size -
schematic would mean, there is a green wire with
Customer supplied the circuit number “F702” stamped on it. This wire is
Consult the schematic for your application for wire the “Rated Speed” signal wire on the 3500B
size recommendation on customer supplied wiring. ADEM-II system wire harness. The “F702” circuit
The circuits breakers inside the E.l.P. are sized to code would be the identification of the “Rated Speed”
work with the wire gauges shown on the schematics. circuit on all Caterpillar 3500B Family of Engines.
Another wire identification on the schematic is the
size of the wire. The size or gauge of the wire is
called “AWG”. The gauge of the wire will follow the
wire color.
For example: A color code of “103-RD-14” on the
schematic would indicate the “103-RD” wire is a
14 AWG wire.
If the gauge of wire is not listed after the wire color,
the gauge of the wire will be 18 AWG.
11
Electrical System Grounding The engine’s alternator, starting motor, and ALL
Requirements electrical systems MUST be grounded to (-) Battery,
and the alternator and starting motor must meet
Proper Grounding marine Isolation requirements.
Proper grounding for vessel and engine electrical For engines which have the alternator grounded to
systems is necessary for proper performance and an engine component, a ground strap MUST connect
reliability. that component to (-) Battery and the component
MUST be electrically isolated from the engine.
NOTICE For engines which are utilizing the throttle
Improper grounding will cause uncontrolled synchronization capability, it is critical that a
and unreliable circuit paths. common ground cable be utilized between the (-)
Battery connections of each engine’s battery sets.
This can result in damage to the engine’s The wire should be a dedicated 00 AWG cable to
crankshaft main bearings, crankshaft journal ensure proper synchronization operation.
surfaces or other engine components, and can
cause electrical activity which may degrade Ground Plate
the boat’s electronics and electrical A ground plate with a direct path to (-) Battery is
communication equipment. permissible to use as a common ground point for the
components of one engine system.
Wire Size
The wire size of a ground plate to which an
alternator is grounded MUST be of adequate size to
handle full alternator charging current.
12
Connecting Programmable Relay
Control Module (PRCM) to EIP
Purpose
To provide a communication link between the Engine Starter Overcrank
ADEM-II/EMS-II System and the PRCM. The PRCM Engine Starter Motor Relay Active
is used by the customer to provide 25 relay outputs EIP ECS Switch not in AUTO position
and six LED outputs from eight Switch Inputs and Engine Power Derating Active
ADEM111/EMS-II System parameters. The PRCM Engine Power Derating Active but not for Altitude
alone controls 7 relays and 6 LED’s. For expansion, Engine Shutdown
the user can add one or two Relay Driver Modules to Engine Low Oil Pressure Shutdown
add an additional 9 or 18 relays. The outputs are Engine Jacket Water Temperature High Shutdown
customer programmable through a keypad and Engine Overspeed Shutdown
display on the PRCM. Engine Crankcase Pressure High Shutdown
Engine Aftercooler Temperature High Shutdown
Value
Provides for customized warning systems using the Function
following ADEM-II/EMS-II System Parameters:
The operator will use the PRCM Keypad and Display
ECM Active Diagnostic Present panel to program the various input/output functions.
ECM Voltage Warning These programmed functions will turn on/off the
Engine Oil Pressure Warning various LED’s and Relays. Refer to Caterpillar
Engine Jacket Water Temperature High Warning Publication SENR6588 Owner’s Manual,
Engine Jacket Water Temperature Low Warning Programmable Relay Control Module for more
Engine Overspeed Warning details.
Engine Air Inlet Restriction Warning
Engine Exhaust Temperature High Warning
Engine Oil Filter Differential Pressure Warning
Engine Fuel Filter Differential Pressure Warning
Engine Crankcase Pressure High Warning
Engine Aftercooler Temperature High Warning
Engine Low Coolant Level Warning
Engine Low Fuel Level Warning
Battery Charger Diagnostic Warning
Marine Gear Oil Temperature High Warning
Marine Gear Oil Pressure Low Warning
Engine Electronic Fuel Injection Disabled
Engine @ 100% Load Factor (i.e. in Rack Limit)
Engine Speed above 50 RPM
13
Connecting Relay & Circuit Breaker
inside EIP for PRCM power control
Purpose Function
To provide a means to switch power to the PRCM via The operator will install the relay, breaker and
the four position Engine Control Switch (ECS) on the associated wiring inside the EiP using the schematic
engine mounted Electronic Instrument Panel (EIP). shown above. The PRCM will be turned on via the
ECS in the “AUTO” (using a Remote Start/Stop
Value Switch), “MAN.START” or “STOP” positions. The
Provides on/off control of the PRCM via the ECS and PRCM will be turned off via the ECS in the “OFF”
short circuit protection. or”AUTO” (using a Remote Start/Stop Switch)
positions.
Note: Neither the Remote E-Stop switch or the EIP
mounted E-Stop Button will remove power from the
PRCM. This is done to maintain relay position status
inside the PRCM in case an
emergency stop is performed.
14
Connecting Programmable Relay
Control Module (PCRM) to one or two
Relay Driver Modules(s)
Purpose
To provide an additional 9 or 18 relays. The outputs
are customer programmable through a keypad and
display on the PRCM.
Value
Allows Customer to expand the number of engine
parameters monitored through the PRCM.
Function

panel to program the various input/output functions.
These programmed functions will turn on/off the
Relays. Refer to Caterpillar Publication SENR6588
Owner’s Manual, Programmable Relay Control
Module for more details.
15
Connecting Relay Driver Module to
Relay Board Assembly
Purpose
Value
Function
16
Connecting to Relay Contacts on
Relay Board Assembly
Note: Do not connect terminals 1, 2, 12 or 40

of the Relay Board Assembly to the Relay
Contact circuits. The relay circuits must be
kept separate from the Relay Driver Module
power, ground and control signals. Also note
that each common connection is fused (see
schematic diagram above).
Purpose
Value
Function
17
Module (CCM) to EIP
Purpose
To provide a two-way communication link between 10) Engine Overspeed Warning
the ADEM-II System and the Operator of a Personal 11) Engine Overspeed Shutdown
Computer or Programmable Logic Controller or other 12) Air Inlet Restriction Warning
device with a RS-232C Port. 13) Air Inlet Restriction Derate
14) Exhaust Temperature Warning
Value
15) Exhaust Temperature Derate
Allows Customer to remotely control and monitor the 16) Oil Filter Differential Pressure Warning
engine. 17) Fuel Filter Differential Pressure Warning
18) Crankcase Pressure Warning
Function 19) Crankcase Pressure Shutdown
20) Crankcase Pressure Derate
The operator will use Caterpillar supplied “basic” PC 21) Aftercooler Water Temperature Warning
software to create Customer Specific Programs. The 22) Aftercooler Water Temperature Shutdown
CCM software can be easily upgraded via “Flash” 23) Aftercooler Water Temperature Derate
memory programming. Refer to Caterpillar 24) Fuel Injection Disabled
Publication SEBU6997 Owner’s Manual, Customer 25) Engine Overcrank
Communication Module for more details. The 26) Air Shut-off Relay Active
following is a list of parameters that can be 27) Start Motor Relay Active
communicated via CCM: 28) Battery Charger Fault Warning
(customer wired)
Status Parameters: 29) Engine Running
30) Engine At Full Load (i.e. at rack limit)
1) Fault Present 31) System not in Auto
2) ECM Voltage Warning 32) High Altitude Derate
3) Engine Jacket Water Temp High Warning 33) Low Engine Coolant Level Warning (if wired)
4) Engine Jacket Water Temp High Shutdown 34) Low Fuel Level Warning (if wired)
5) Engine Jacket Water Temp High Derate 35) Engine Diagnostic Active
6) Engine Jacket Water Temp Low Warning 36) Backup ECM Ready
7) Engine Oil Pressure Low Warning 37) Backup ECM Online
8) Engine Oil Pressure Low Shutdown 38) Marine Gear Oil Pressure Warning
9) Engine Oil Pressure Derate (customer wired)
39) Marine Gear Oil Temperature Warning
(customer wired)
18
Connecting Customer Communication Control Parameters:
Module (CCM) to ElP-Continued from 1) Remote Start/Stop - EPG Only
previous page 2) Emergency Stop- EPG Only
3) Fault Reset
Operating Parameters: 4) Activate Idle/Rated Speed Contact
1) Engine Speed (w/EMCP 11) - EPG Only
2) Instantaneous Fuel Rate 5) Activate Circuit Breaker Shunt Trip
3) Total Fuel Consumed (w/EMCP 11) - EPG Only
4) Engine Hours 6) Override Cooldown Timer- EPG Only
5) Engine Oil Pressure
6) Engine Coolant Temperature
7) System Voltage
8) Engine Fuel Pressure
9) Exhaust Manifold Temperature
(Turbine Inlet)-RH
10) Exhaust Manifold Temperature
(Turbine Inlet)-LH
11) Air Inlet Restriction - RH
12) Air Inlet Restriction - LH
13) Fuel Filter Differential Pressure
14) Oil Filter Differential Pressure
15) Turbo Outlet Pressure (Boost)
16) Separate Circuit Aftercooler Coolant
Temperature
17) Engine Oil Temperature (GSE Only)
18) Inlet Air Temperature (GSE Only)
19) Marine Gear Oil Pressure (if sensor
installed/wired)
20) Marine Gear Oil Temperature
(if sensor installed/wired)
21) Crankcase Pressure
19
Module (CCM) to a Modem
Purpose Function
To provide a two-way communication link between The operator will use Caterpillar supplied “basic” PC
the CCM and a remote operator of a Personal software to create Customer Specific Programs. The
Computer or Programmable Logic Controller or other CCM software can be easily upgraded via “Flash”
device with a RS-232C Port. memory programming. Refer to Caterpillar
Publication SEBU6997 Owner’s Manual, Customer
Value
Communication Module for more details.
Allows Customer to remotely control and monitor the
engine.
20
Connecting Customer
Communication Module(CCM) to a
Personal Computer
Purpose Function
the CCM and an operator of a Personal Computer or software to create Customer Specific Programs. The
Programmable Logic Controller or other device with CCM software can be easily upgraded via “Flash”
a RS-232C Port. memory programming. Refer to Caterpillar
Value
Allows Customer to control and monitor the engine
from another location in close proximity to the
engine.
21
Connecting Customer
Communication Module (CCM) to a
Satellite Receiver/Transmitter
Purpose Function
the CCM and a remote operator of a Personal software to create Customer Specific Programs. The
Computer or Programmable Logic Controller or other CCM software can be easily upgraded via “Flash”
device with a RS-232C Port via Satellite. memory programming. Refer to Caterpillar
Value
Allows Customer to remotely control and monitor the
engine.
22
Connecting a Remote Start/Stop
Switch to the EIP
Purpose
Provides a remote means to start, run and The Operator must first verify that the Remote
cooldown/stop the engine. Start/Stop Switch is set to the “STOP” position. The
operator will secondly set the EIP mounted Engine
Note: This function is only available while the
Control Switch (ECS) to the “AUTO” (3 O’Clock)
Electronic Instrument Panel (EIP) mounted Engine
Position. Finally, to start/run the engine, the
Control Switch (ECS) is in the “AUTO” (3 O’Clock)
operator must move the Remote Start/Stop Switch to
Position.
the “Start/Run” position. To cooldown/stop the engine
Value the operator will move the Remote Start/Stop Switch
to the “Cool/Stop” position
Adds operator convenience. Start/Run/Stop control of
the engine can be accomplished from a remote
Finally, to stop the engine without cooldown the
location with only 5 wires and a switch.
operator must move the Remote Start/Stop Switch to
Function the “Stop” position.
Note: Only one Remote Start/Stop Switch is

WARNING
allowed per engine. The ADEM-II System will not
function with more than one Remote Start/Stop
Starting the engine when a person is working
Switch. For example, applications that have a Pilot
on or near the unit could result in injury or
House Control Panel that includes a Remote
death. Always insure that no one is near the
Start/Stop Switch function must not add on
engine when it is started or whenever the
another Remote Start/Stop Switch to the ADEM-II
Engine Control Switch (ECS) is placed in
System.
“AUTO” (3 O’Clock) position.
23
Connecting a Remote E-Stop Switch
to the EIP
Purpose
Provides a remote means to stop the engine. The Remote E-Stop Switch is used to shut down the
engine during an emergency situation by signaling
Note: This function is available while the Electronic the ECM to disable fuel injection, and actuate both
Instrument Panel (EIP) mounted Engine Control air shutoff’s if present and enabled for use via the
Switch (ECS) is in the “AUTO” (3 O’Clock), “MAN. ET Service Tool.
START (6 O’Clock) and “COOLDOWN STOP”
(9 O’Clock) Positions. Note: The EIP mounted Emergency Stop push
Value button has a protective cover around it to prevent
inadvertent operation. Refer to SENR6587 Service
Adds operator convenience. E-Stop control of the Manual, 3500B Electronic Instrument Panel for
engine can be accomplished from a remote location more details.
with only 3 wires and a switch.
Function
NOTICE
Emergency Shutoff controls are for
EMERGENCY use ONLY. DO NOT use
Emergency shutoff devices or controls for
normal stopping procedure. Refer to the
Engine Stopping section of Caterpillar
Publication SEBU6917 for normal stopping
procedures.
24
Connecting a Coolant Level Sensor
to the EIP
Purpose Function
To provide a Low Coolant Level indication to the The operator will use the EMS-II LED corresponding
operator. to Low Coolant Level indication on the Electronic
Instrument Panel (EIP) to monitor low coolant level
Value
in the Radiator (Gensets) or Expansion Tank
Adds a monitoring function to aid the operator in (Marine). Refer to SENR6587 Service Manual, 3500B
maintaining proper coolant volume in the engine and Electronic Instrument Panel for more details. Low
therefor preventing engine overheating. coolant level will have a negative impact on engine
life.
Note: Using this Sensor, the operator can also

receive an Engine Low Coolant Level Warning
indication via the PRCM.
25
Connecting a Fuel Level Switch
to the EIP
Purpose Function
To provide a Low Fuel Level indication to the The operator will use the EMS-II LED corresponding
operator. to Low Fuel Level indication on the Electronic
Instrument Panel (EIP) to monitor low fuel level in
Value the supply tank. Refer to SENR6587 Service Manual,
Aids the operator in preventing unexpected engine 3500B Electronic Instrument Panel for more details.
shutdown because of an empty fuel supply tank. Note: Using this Switch, the operator can also
receive an Engine Low Fuel Level Warning
26
Connecting a 4-20 mA Convertor for
Throttle Input to Engine Electronic
Control System (Marine Propulsion
Only)
Purpose Function
Provides an isolated interface between industry Converts 4-20 mA throttle signal to Caterpillar
standard 4-20 mA analog input signal and the Standard Pulse Width Modulated format.
Caterpillar Standard Pulse Width Modulated format.
Value
Eliminates the need for customer to custom design
pulse width modulated driver modules.
27
Throttle and Engine Synchronization
System for Dual Engine control
(Marine Propulsion Only)
Purpose
To link the engine controls of both engines to a single The Operator will set the Synchronization Switch
throttle. and then adjust the throttles to bring the engine
speeds within 50 rpm of each other. The Engine
Value
controls will detect if and when the engine speeds
Adds operator convenience, vessel control and is a are within 50 rpm of one another and then lock onto
standard practice in marine applications. the “Master” throttle for engine speed control.
Function Note: Synchronization can only occur when both
engine speeds are within 50 rpm of each other.
The operator will use the Synchronization Switch to Likewise, unsynchronization can only occur when
transfer the control of both engines to a single both engine speeds are within 50 rpm of each other.
throttle lever. The Electronic Control Module (ECM)
will then control engine speed from the “Master”
throttle lever. Engine synchronization can be
transferred to either the PORT or STARBOARD
(STBD) throttle.
28
System for Triple Engine control by
CENTER Throttle (Marine Propulsion
Only)
29
Purpose The Operator will set the Synchronization Switch
and then adjust the PORT and STARBOARD
To link the engine controls of all three engines to a throttles to bring their engine speeds to within
single throttle. 50 rpm of the CENTER engine. The Engine controls
Value will detect if and when the PORT and STARBOARD
engine speeds are within 50 rpm of the CENTER
Adds operator convenience, vessel control and is a engine and then “lock” onto the CENTER throttle for
standard practice in marine applications. engine speed control.
Function Note: Synchronization can only occur when all
The operator will use the Throttle Synchronization engine speeds are within 50 rpm of one another.
Switch to transfer the control of all three engines to Likewise, unsynchronization can only occur when all
the CENTER throttle lever. The Electronic Control engine speeds are within 50 rpm of one another.
Module (ECM) of each engine will then govern
engine speed from the CENTER Engine throttle
signal.
Note: Engine synchronization can not be transferred
to either the PORT or STARBOARD (STBD) throttle
control. Engine speeds can only be synchronized to
the CENTER throttle control.
30
System for Triple Engine control by
PORT Throttle (Marine Propulsion
Only)
31
Throttle Position Sensor Calibration • Turn ECS to “Cool Down/Stop” (9 O’clock) position.
(Marine Propulsion Only) • Access the Monitor Throttle Position Sensor Signal
screen to display the Duty Cycle.
Inspect Throttle Linkage
Adjust the throttle linkage, with the throttle at LOW
Inspect the Throttle linkage for: IDLE position, until:
• Loose, bent, broken, missing, worn components. • The Duty Cycle reading (display) is between 5%
Also, inspect for interface with the linkage or return and 10%.
spring. Note: After adjustment, a slight movement OFF
Throttle linkage should work smoothly without (away from) the LOW IDLE linkage stop should
excessive drag, and return to LOW IDLE position increase the Duty Cycle reading.
WITHOUT assistance in less than one second. When properly adjusted, the rotary disc should be
Adjustment at Low Idle Stop Position positioned as shown in Illustration 1 when the
(Minimum Throttle) throttle is in the LOW IDLE position.
The calibration of the throttle position sensor

requires the use of an IBM PC compatible Laptop
Computer “/Communication Adapter and Caterpillar
ET Software. Run ET and from the first screen
“Click” on the “Service” pull-down menu.
Adjustment at High Idle Stop Position

(Maximum Throttle)
Adjust the throttle linkage, with the throttle at LOW
IDLE position, until:
• The Duty Cycle reading (display) is between 90%
and 95%.
When properly adjusted, the rotary disc should be
positioned as shown in Illustration 2 when the
throttle is in the HIGH IDLE position.
Repeat the adjustment at LOW IDLE position to

verify that the LOW IDLE stop is still properly
adjusted.
• Turn ECS (Engine Control Switch) to OFF

position.
• Connect to the ECAP or ET System
32
Connecting Backup Throttle Position
Sensor for Single Engine Installation
Purpose Function
To provide Throttle Position Sensor redundancy. The operator will use a switch to transfer the control
of the engine to the Backup Throttle Position Sensor.
Value
The Electronic Control Module (ECM) will then
Adds operator convenience. If diagnostic problem is control engine speed from the Backup throttle lever.
identified on Primary Throttle then simply select the
Backup Throttle via the Throttle Selection Switch.
33
Connecting Premium Pilot House
Panel w/Switches to EIP (Marine
Propulsion Only)
Purpose LCD Display

To provide engine monitoring information and 20. Engine Speed in RPM
START/STOP Control to the Pilot House. 21. Instantaneous Fuel Consumption
22. Percent Load
Value 23. Engine Hours
Provides for monitoring of the following information: 24. Active Gauge value
Warning Indicator Lights

1. Shutdown/Diagnostic
2. System Voltage
3. Overspeed
4. Low Transmission Oil Pressure
5. High Transmission Oil Temperature
6. Low Oil Pressure
7. High Coolant Temperature
8. Low Coolant Temperature
9. Low Coolant Level
10. Low Fuel Level
Gauges
11. Engine Oil Pressure
12. Engine Coolant Temperature Function
13. Marine Gear Oil Pressure The operator will use a Selector Switch to
14. Marine Gear Oil Temperature START/STOP the engine, a Scroll Switch to access
15. Left Hand Exhaust Manifold Temperature the various LCD & LCD/Gauge functions, a dimmer
16. Right Hand Exhaust Manifold Temperature knob to darken/lighten the backlighting, a
17. Turbo Outlet Pressure (Boost) “mushroom” switch for emergency stop and lastly
18. Aftercooler Temperature two lights to monitor Back-Up Engine Control
19. Tachometer READY and ACTIVE.
34
w/Switches to EIP (Marine
Propulsion Only)
Purpose LCD Display

To provide basic engine monitoring information and 16. Engine Speed in RPM
START/STOP Control to the Pilot House. 17. Instantaneous Fuel Consumption
18. Percent Load
2. System Voltage
3. Overspeed
6. Low Oil Pressure
10. Low Fuel Level
Gauges
11. Engine Oil Pressure Function
12. Engine Coolant Temperature
13. Marine Gear Oil Pressure The operator will use a Selector Switch to
14. Marine Gear Oil Temperature START/STOP the engine, a Scroll Switch to access
15. Tachometer the various LCD & LCD/Gauge functions, a dimmer
knob to darken/lighten the backlighting, a
“mushroom” switch for emergency stop and lastly
two lights to monitor Back-Up Engine Control
READY and ACTIVE.
35
w/o Switches to EIP (Marine
Propulsion Only)
Purpose LCD Display

To provide basic engine monitoring information to 16. Engine Speed in RPM
the Pilot House. 17. Instantaneous Fuel Consumption
18. Percent Load

2. System Voltage
3. Overspeed
6. Low Oil Pressure
10. Low Fuel Level
Gauges Function
11. Engine Oil Pressure The operator will use the Scroll Switch to access the
12. Engine Coolant Temperature various LCD & LCD/Gauge functions and a dimmer
13. Marine Gear Oil Pressure knob to darken/lighten the backlighting.
14. Marine Gear Oil Temperature
15. Tachometer
36
Using CCM as a CAT Data Link
Signal Booster
Purpose
To provide a boosted CAT data link signal. The illustration on the following page shows a
sample installation using multiple Pilot House
Value
Panels. The CCM may be connected wherever it is
Allows Customer to remotely control and monitor the convent to do so, and does not necessarily need to be
engine at distances beyond the standard 30 m in series with the panel or PRCM. Segment length
(100 ft.) data link limit. may vary and does not necessarily need to be in
equal proportions between modules. The sum of all
Function segments must be less than or equal to 455 m
The limitation on the distance to mount pilot house (1500 ft.).
panel and PRCM components is currently 30 m
(100 ft.). A CCM can be added to the system to allow
the devices to be installed up to 1500 ft. from the
engine. The CCM acts as a constant current source
to overcome the impedance of extended length of
communication link wire.
37
General CCM Installation Information Note: Do not mount the CCM on an engine or within
an engine mounted enclosure. It is not designed for
When a CCM is installed, these requirements must this environment.
be met:
• The environmental, mounting, wiring, and cable General Wire and Cable Specifications
specifications must be met. The following specifications for wire and cable is
• The connections diagrams must be followed. given to reduce voltage drops over long runs of wire
and to reduce EMI/RFI interference.
Specifications • The wires connected to B+ and B- on the CCM
must be at least 16 AWG.
• The ambient operating temperature range is from
-40°C to + 70°C (-40°F to + 158°F). • Maximum CAT Data Link cable and ± B wire
length is 455 m (1500 ft.), including wire runs
• The storage temperature range is from between any multiple panels.
-40°C to + 85°C (-40°F to + 185°F).
• No terminations or splices allowed on the above
• The unit must be protected from direct contacts wires, except as noted in the connection diagrams.
with liquids (splash-proof). If sealing is required,
the CCM must be in a water-tight enclosure. • The cable connected to CAT Data Link ± must be
16 AWG, shielded twisted pair cable. Use
Mounting 123-2376 Electric Cable, Belden 8719 Cable, or
The CCM should be located on a desk or shelf. The equivalent.
rubber feet on the bottom of the CCM can also be
removed to allow panel mounting.
38
Connecting a Marine Gear Oil
Pressure Sensor to the EIP (Marine
Propulsion Only)
Purpose Function
To provide a Marine Gear Oil Pressure indication to The operator will use the EMS-II Gauges on the
the operator. Electronic Instrument Panel (EIP) to monitor Marine
Gear Oil Pressure. Refer to SENR6587 Service
Value Manual, 3500B Electronic Instrument Panel for
Aids the operator in maintaining proper Marine more details.
Gear Oil Pressure. Note: Using this Sensor, the operator can also
receive a Marine Gear Oil Pressure Low Warning
39
Connecting a Marine Gear Oil
Temperature Sensor to the EIP
Purpose Function
To provide a Marine Gear Oil Temperature The operator will use the EMS-II Gauges on the
indication to the operator. Electronic Instrument Panel (EIP) to monitor Marine
Gear Oil Temperature. Refer to SENR6587 Service
Value Manual, 3500B Electronic Instrument Panel for
Aids the operator in maintaining proper Marine more details.
Gear Oil Temperature. Note: Using this Sensor, the operator can also
receive a Marine Gear Oil Temperature High
Warning indication via the PRCM.
40
Connecting a Danfoss (or similar)
Shutdown Switch to the EIP for use
with PHP with Start/Stop & E-Stop
Switches (Marine Propulsion Only)
Purpose monitoring system does not currently allow for

Provides a means to stop the engine via a remote dry engine shutdowns, except for engine overspeed
contact switch. shutdown.
Value Low oil pressure & high jacket water temperature

Danfoss contactors are available through the Price
Provides shutdown function interface for the List. However, other manufacturer switches may be
operator to allow the use of dry contact switches to utilized, as well as additional switches for other
shutdown the engine for conditions defined by the desired parameters.
operator for engine/vessel protection.
The momentary or time delay switch serves two
Function basic purposes. First, it is required during start-up
for a low oil pressure switch as an override until
NOTICE engine oil pressure builds up sufficiently. A time
Emergency Shutoff controls are for delay of 8-9 seconds would provide acceptable
EMERGENCY use ONLY. DO NOT use performance. Second, a momentary switch would
Emergency shutoff devices or controls for provide a means for override of any switch shutdown
normal stopping procedure. Refer to the condition for emergency engine operation or
Engine Stopping section of Caterpillar troubleshooting.
Publication SEBU6917 for normal stopping If more than one shutdown switch is utilized, the
procedures. switches must be connected in series on the 99~BR
wire.
The Shutdown Switch is used to shut down the This shutdown switch wiring instruction is not
engine during an emergency situation or condition by intended to meet Unattended Machinery Space
signaling the ECM to disable fuel injection, and marine society certification requirements. If this
actuate both air shutoff’s if present and enabled for criteria must be met, please contact the factory for
use via the ET Service Tool. The marine engine ECM further instruction.
41
Connecting a Woodward Loadshare
Module to the EIP (Generator Sets
Only)
Purpose Function
To provide a means of sharing load with multiple The operator will use the Woodward Loadshare
generator sets. Module’s PWM OUTPUT SIGNALS (+) & (-) to
provide a “Desired Engine Speed” signal to the
Value ADEM-II ECM. Refer to SENR6587 Service Manual,
Allows Woodward Loadshare Module to control 3500B Electronic Instrument Panel for more details.
engine speed. Note: The 9X-9591 Speed Control inside of the
Electronic Instrument Panel (EIP) must be removed
if present and the “F702-GN” wire connected to the
“S” Terminal of the 9X-9591 must then be connected
to Pin-36 of the 40-Pin Customer Connector.
42
Connecting a Speed Adjust
Potentiometer to the EIP (Generator
Sets Only)
Purpose Function
To provide a means of controlling engine speed on The operator will use the Speed Adjust
Generator Sets using the 9X-9591 Speed Control. Potentiometer to vary the “Desired Engine Speed”
PWM signal’s pulse width. This signal is inputted to
Value the ADEM-II ECM which in turn governs “Actual
Allows the operator to adjust the 9X-9591 Speed Engine Speed”.
Control’s “Desired Engine Speed” Pulse Width
Modulated (PWM) output signal. The 9X-9591 Speed
Control resides inside the Electronic Instrument
Panel (EIP). Refer to SENR6587 Service Manual,
3500B Electronic Instrument Panel for more details.
43
Connecting an Air Temperature
Sensor to the EIP (Generator Sets
Only)
Purpose Function
To provide temperature measurement of the intake The operator will use the EMS-II Gauges on the
air prior to entering the cylinder head. Electronic Instrument Panel (EIP) to monitor inlet
air temperature. Refer to SENR6587 Service
Value
Manual, 3500B Electronic Instrument Panel for
Aids detection of degraded aftercooler performance, more details. Temperatures 30°C greater than
and high ambient air temperatures or poor air Aftercooler Water Temperature will have a negative
ventilation in the area immediately next to engine impact on engine performance.
air filters.
44
Connecting an Engine Oil
Temperature Sensor to the EIP
(Generator Sets Only)
Purpose Function
To provide temperature measurement of the engine The operator will use the EMS-II Gauges on the
oil before filtering. Electronic Instrument Panel (EIP) to monitor oil
temperature. Refer to SENR6587 Service Manual,
Value
3500B Electronic Instrument Panel for more details.
Aids detection of degraded oilcooler performance. Temperatures greater than 107°C will
have a negative impact on engine life.
45
Connecting a Battery Charger Fault
Switch to the EIP (Generator Sets
Only)
Purpose
NOTICE
To provide a means of indicating a failing battery If the engine has been shut down, and a
charger to the operator. restart
is needed, and the battery voltage is below
Value 14.4 Volts DC with the ADEM-II system pow-
Allows the operator to prevent an undesired engine ered but prior to Cranking the starters then
shutdown caused by a battery charger failure. the engine
may not restart. This is because the ECM
Function Relay (ECMR) inside of the Electronic
The operator will use the EMS-II “System Voltage” Instrument Panel (EIP) has a minimum pull-
warning LED on the Electronic Instrument Panel in voltage of 14.4 Volts DC. The relay’s con-
(EIP) to monitor the battery charger. Refer to tacts supply (+) Battery
SENR6587 Service Manual, 3500B Electronic voltage to the ECM. If the relay contacts do
Instrument Panel for more details. If a battery not close then the ECM will not power-up.
charger failure occurs, the ADEM-II ECM will The relay’s
continue to govern the engine down to a minimum minimum hold-in voltage is 7.0 Volts DC.
battery voltage of 10 Volts DC.
Note: Using this Switch, the operator can also
receive a Battery Charger Diagnostic Warning
46
Adding circuits inside EIP for CCM
power control (Genset & Marine
Auxiliary Applications ONLY)
Purpose Function
To provide a means to switch power to the CCM
The operator will install the wiring inside the EIP
(Customer Communication Module) via the four
using the schematic shown above. The CCM will be
position Engine Control Switch (ECS) on the engine
turned on via the ECS in the “AUTO” (using a
mounted Electronic Instrument Panel (EIP).
Remote Start/Stop Switch), “MAN.START” or”STOP”
Value positions. The CCM will be turned off via the ECS in
the “OFF” or “AUTO” (using a Remote Start/Stop
Provides on/off control of the CCM via the ECS and
Switch) positions.
short circuit protection.
Note: Using the Remote E-Stop switch function
will not remove power from the CCM. Using the
EIP mounted E-Stop Button will remove power
from the CCM.
47
Connecting Customer
Communication Module (CCM) to an
Engine Vision Display (Marine
Propulsion Only)
Purpose Function
the CCM and the Engine Vision Display. software to create Customer Specific Programs. The
CCM software can be easily upgraded via “Flash”
Value
memory programming. Refer to Caterpillar
Allows Customer to remotely monitor the engine. Publication SEBU6874 Owner’s Manual, Customer
48
Wiring Diagrams and Wiring Groups
Use the following information with caution, as the part numbers are subject to change.
Engine Wiring Diagram Wiring Diagram
Number Form Number
Gen Set (EMCP II) 121-2027 SENR1004
Gen Set (engine only) 125-9744 SENR1005
Marine Engine (Dual ECM) 126-7150 SENR1009
Marine Auxiliary Engine (Single ECM) 126-9193 SENR1010
49
Considerations in Providing The following customer connections are
Electrical Power to the optional:
3500B Marine Engine • Remote Start/Stop switch
(Questions heard and answered during Field Engine • Emergency stop switch
Installation) • Remote annunciation of water temperature and oil
pressure fault conditions
What is the acceptable voltage range for input
to the Series B engine? What will be the effects Additional system considerations are useful
of the momentary loss of power while and should be considered:
switching to a backup battery set?
• Backup battery and its control switch
The recommended voltage range is 20 to 28 volts.
The Smart Engine Monitoring System (SEMS) will • Backup throttle and its control switch
annunciate an alarm condition if the voltage falls
outside this range. A back-up battery set should be Attachments:
brought on line as soon as the primary system • Remote SEMS, up to 4 additional units
voltage falls outside the recommended range. (in addition to engine mounted unit). Only
“Make before break” contacts are preferred. available on marine engines. Wire to remote
SEMS must be a twisted pair (one 360° twist
The engine will continue to run as voltage falls. The per in).
first system to drop out will be SEMS. This system • Automatic pneumatic or 24 volt direct current
will not function correctly below 18 volts. However, electric prelube, AC
this will not effect engine operation. The engine will
continue to run to as low as 10 volts. However, • Automatic Ether starting aid control with manual
components are not designed to operate in this mode injection override, EPG engine only
indefinitely and operation at this voltage level is • Air Inlet Shutoffs, with 75% overspeed verify
highly discouraged. A temporary loss of power (as in switch located inside control box
one or two milli-seconds when switching) will not • 2301A Woodward Load Share Module, designed
effect engine operation. The engine will continue to specifically for Caterpillar Electronic Engine,
run normally. A loss of power for a longer period instead of a 4-20 milliamp actuator, it incorporates
(over 0.25 seconds) could cause the engine to stop the Caterpillar pulse width modulated throttle
running, depending on injection duration and other signal
loads on the ECM.
In designing the engine's power supply, how
What connections are necessary to be made by much of what type power should be provided
the customer? What options are available? to the engine?
There are only two absolutely necessary customer A minimum of 10 amps of 24 volt direct current
connections: power.
• “Throttle sensor”, which tells the engine at what Should you run wires to remote annunciation
speed you want it to run sites in anticipation of future remote displays?
• Power supply Yes, but do not connect to the customer connection
until the remote displays are installed. If runs of
unused wire are connected without remote displays,
there is a risk of malfunction of existing displays.
50
Electronic Control Analyzer display the status of up to eight sensors or switches,
and Programmer (ECAP) print parameters when used with the 8C9700
Rechargeable Portable Printer, and can be used with
The basic ECAP tool needs a small plug-in module, multiple Service Program Modules.
called a Service Program Module (SPM NEXG4521),
to adapt the basic ECAP tool to the 3500B EPG The following table outlines the tools and cables
Diesel Engine application. The ECAP can program needed to use the ECAP to service the 3500B EPG
some, but not all System Configuration Parameter, Diesel Engine.
3500B EUI Electronic Service Tools

Electronic Control Analyzer Programmer
Part Number Description

1
8T86 97 Electronic Control Analyzer Programmer (ECAP). Displays codes, values, pulse
width modulated (PWM) signals (with PWM adapter), displays and programs parameters
and calibrates certain sensors.
2
NEXG4521 Machine Functions Duel SPM For 8T8697 ECAP.
3
7X1700 Communication Adapter Group for use between ECAP tool and ECM.
Includes 7X1701 Communication Adapter Tool, 6V3072 Case, 7X1424 Block,
7X1571 Fuse, 7X1569 Fuse, NEEG2464, SEHS9264.
2
NEXG4523 SPM for 7X 1700 Communication Adapter Group.
7X1420 Connector Cable (CA tool to ECAP). Connects ECAP to Communication

Adapter tool Fits old style ECAP with Plastic Connector
7X1570 Connector Cable (CA tool to ECM) Connects 3500B EUI ECM to
Communication Adapter tool.
7X1851 Connector Cable (CA tool to ECAP) Connects ECAP to Communication

Adapter tool. Fits new style ECAP with Metal Connector.
7X1703 Communication Adapter Mounting Plate.
8C9801 Pulse Width Modulated Signal Adapter Group

1
Refer to Special Instruction, SEHS8742, Using the 8T8697 Electronic Control Analyzer and Programmer (ECAP) and SEHS9343.
2
This is a Subscription, since it is anticipated that it will be changing at regular intervals.
3
Refer to Tool Operating Manual SEHS9264., Installation and Use of the 7X1701 Communication Adapter Tool.
Additional tooling
There are several adapter cables, probes, etc., that Either the heavy duty multimeter or the standard
are used with the service tools. These allow the duty multimeter (listed in the chart) are suitable for
mechanic to gain access, for diagnosis, to wires making the necessary voltage and resistance
carrying voltages and signals. measurements on the 3500B EPG Diesel System.
These tools are listed in the chart along with their
part numbers.
51
Electrical Connectors 4. Perform 44.5 N (10 lb) pull test on each pin/wire.
Many of the procedures in this guide will direct you Each pin and connector should easily withstand
to a specific electrical connector. Use the following to the pull test value and remain in the connector
help determine the connector. body. This test ensures the wire was properly
crimped in the pin, and the pin properly inserted
1. Check to make sure all seals are present and in the connector.
properly seated. Check pins and sockets before The “DT” connectors use an orange wedge to lock the
joining connectors. Verify proper alignment and pins in place. Ensure that the orange wedge is
locations of pins and sockets in each connector. properly installed.
2. Check “DT” connector locking and “HD” connector
lock ring. Make sure that the connector is Note: Do Not solder pins/wires. Always crimp pins
properly locked (you will hear an audible “click”) onto the wires using the 1U5804 Deutsch Crimp
together and that the two mating halves cannot Tool.
be pulled apart.
3. Do Not exceed 2.25 N•m (20 lb in) of torque on the
ECM connector bolt when connecting the 40-pin
“DRC” connector to the ECM. Make sure the
connector bolt is properly tightened.
52
3500B EPG Diesel Electronic 3500B Electronic Control Module (ECM). ET is the
Preferred tool due to its increased functionality,
Service Tools however, the ECAP can be used to perform basic
The Caterpillar Service Tools for the 3500B EPG troubleshooting.
Diesel System are designed to help the service
technician analyze and locate problems within the
system. Their use is required in order to perform
Electronic Technician (ET)
sensor calibrations and to read or change ET consists of an IBM compatible computer (laptop)
programmable engine parameters. and software programs. The software programs
allow the laptop to program ECM parameters, read
Two Service tools can be used with the 3500B EPG and display sensor values and switches, perform
Diesel engine. The Electronic Technician (ET) or the diagnostic test and calibrate sensors.
Electronic Control Analyzer and Programmer
(ECAP). With either ET or ECAP, a Communication The following table outlines the tools and cables
Adapter tool is required to communicate with the needed to use ET to service the 3500B EPG:
3500B EPG Diesel Electronic Service Tools


1
None IBM PC Compatible - Minimum of 386 (25 mHz)
1
JERD 2124 Single User License for ET version 1.4 (Main ET Program) (Min)
1
JERD 2129 Data subscription for all engines and machines.
(Allows ET to communicate with 3500B engines.)
3
7X1700 Communication Adapter Group for use between ET Tool and ECM.
7X1571 Fuse, 7X1569 Fuse, NEEG2464m and SEHS9264
2
NEXG4523 SPM for 7X1700 Communication Adapter Group.
7X1688 Connector Cable (CA to PC) Connects PC (laptop) to Communication Adapter.
7X1570 Connector Cable (CA to ECM) Connects 3500B EPG Diesel ECM to Communication
Adapter tool.
7X1412 Connector Cable - (CA to ECM) ATA Cable connection.

1
Contact the PC hotline at 1-800-THE-PCDR (843-7237) for more information.
2
This is a subscription, since it is anticipated that it will be changing at regular intervals.
3
Refer to Tool Operating Manual SEHS9264, Installation and Use of the 7X1701 Communication Adapter Tool.
53
EPG Engine Customer Programmable Options
(Using Service Tools)
High Low
Coolant Coolant Air Inlet Exhaust Oil Filter Fuel Filter Crankcase Aftercooler
Voltage Temperature Temperature Overspeed Restriction Altitude Temperature Differential Differential Pressure Temperature Oil Pressure
Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring
Off Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional
Warning Default Optional Default Optional Optional Optional Optional Default Default Optional Default Optional
Derate N/A Optional N/A N/A Default Default Default N/A N/A N/A Optional N/A
Shutdown N/A Default N/A Default N/A N/A N/A N/A N/A Default Optional Default
Default Delay
Time for
Warning
Mode 10 seconds 5 seconds 5 seconds 0 seconds 5 seconds N/A 5 seconds 5 seconds 5 seconds 3 seconds 5 seconds 4 seconds
Default Trip
Point for
Warning 1.18 x See Chart
Mode 20.0 volts 102.0°C 80.0°C rated speed 7 Kpa N/A from 2T spec 105 Kpa 70 Kpa 2.0 Kpa 102.0 Kpa Below
Default Delay
Time for Start
Derate
Mode N/A 30 seconds N/A N/A 5 seconds N/A 5 seconds N/A N/A N/A N/A N/A
Default Step
Delay Time
for Derate
Mode N/A N/A N/A N/A N/A N/A 15 seconds N/A N/A N/A N/A N/A
Default Trip
Point for
Derate Mode N/A 125.0°C N/A N/A 7 Kpa from 2T spec from 2T spec N/A N/A 6.0 Kpa 125°C N/A
Default Delay
Time for
Shutdown
Mode N/A 5 seconds N/A 0 seconds N/A N/A N/A N/A N/A 3 seconds 5 seconds 9 seconds
Default Trip
Point for
Shutdown 1.18 x
Mode N/A 107.0°C N/A rated rpm N/A N/A N/A N/A N/A 3.5 Kpa 107.0°C MAP
54
EPG Engine Factory Programmable Options
(Section 1)
High Low
Voltage Oil Pressure Temperature Temperature Overspeed Restriction Altitude Temperature Differential Differential Pressure Temperature
Warning Default Optional Optional Default Optional Optional Optional Optional Default Default Optional Default
Derate N/A N/A Optional N/A N/A Default Default Default N/A N/A N/A Optional
Shutdown N/A Default Default N/A Default N/A N/A N/A N/A N/A Default Optional
Startup
Delay Time N/A 10 seconds N/A 10 minutes N/A N/A N/A N/A N/A N/A N/A N/A
Time to Reach
Maximum
Derate N/A N/A 480 seconds N/A N/A N/A N/A N/A N/A N/A 480 seconds 480 seconds
Hysterisis 2 MAP 5 N/A 100 N/A N/A 10 10 10 0.25 3
Security Level 1 3 1 1 3 1 3 3 1 1 3 1
Maximum
Derate
Percent or
Derate Step N/A N/A 25 N/A N/A 2% / KPA 3% / 305m 2% / step N/A N/A N/A 25
Filter Factor N/A N/A N/A N/A N/A 2 N/A N/A N/A N/A N/A N/A
Maximum
Restriction N/A N/A N/A N/A N/A 25 N/A N/A N/A N/A N/A N/A
Maximum
Derate N/A N/A N/A N/A N/A N/A 35% N/A N/A N/A N/A N/A
Derate
Latched N/A N/A N/A N/A N/A N/A N/A NO N/A N/A N/A N/A
55
EPG Engine Factory Programmable Options
(Section 2)
High Low
Default Delay
Time for
Warning
Mode 10 seconds 4 seconds 5 seconds 5 seconds 0 seconds 5 seconds N/A 5 seconds 5 seconds 5 seconds 3 seconds 5 seconds
Minimum
Delay Time
for Warning
Mode 1 seconds 1 seconds 1 seconds 1 seconds 0 seconds 1 seconds N/A 1 seconds 1 seconds 1 seconds 1 second 1 seconds
Maximum
Delay Time
for Warning
Default Trip
Point for
Warning 1.18 x
Mode 20.0 volts MAP 102.0°C 80.0°C rated speed 7 Kpa N/A from 2T spec 105 Kpa 70 Kpa 2.0 Kpa 102.0°C
Minimum
Trip Point
for Warning
Mode 20.0 volts MAP 90.0°C 63.0°C 1200 rpm 3 Kpa N/A 500.0°C 70 Kpa 50 Kpa 0.5 Kpa 90.0°C
Maximum
Trip Point
for Warning
Default Delay
Time for
Start Derate
Mode N/A N/A 30 seconds N/A N/A 5 seconds N/A 5 seconds N/A N/A 10 seconds 5 seconds
Minimum
Delay Time
for Start
Derate Mode N/A N/A 1 second N/A N/A 1 second N/A 1 second N/A N/A 1 second 1 second
Maximum
Delay Time
for Start
Derate Mode N/A N/A 60 seconds N/A N/A 60 seconds N/A 60 seconds N/A N/A 60 seconds 60 seconds
Default
Step Delay
Time for
Derate Mode N/A N/A N/A N/A N/A N/A N/A 15 seconds N/A N/A N/A N/A
Minimum
Step Delay
Time for
Maximum
Step Delay
Time for
Default
Trip Point for
Derate Mode N/A N/A 125.0°C N/A N/A 7.0 Kpa from 2T spec from 2T spec N/A N/A 6.0 Kpa 125.0°C
Minimum
Trip Point for
Derate Mode N/A N/A 90.0°C N/A N/A 1.0 Kpa 250 meters 500.0°C N/A N/A 0.5 Kpa 90.0°C
Maximum
Trip Point for
Default
Delay Time
for Shutdown
Mode N/A 9 seconds 5 seconds N/A 0 seconds N/A N/A N/A N/A N/A 3 seconds 5 seconds
Minimum
Delay Time
for Shutdown
Mode N/A 1 seconds 1 seconds N/A 0 seconds N/A N/A N/A N/A N/A 1 seconds 1 second
Maximum
Delay Time
for Shutdown
Default
Trip Point
for Shutdown 1.18 x
Mode N/A MAP 107.0°C N/A rated rpm N/A N/A N/A N/A N/A 3.5 Kpa 107.0°C
Minimum
Trip Point
for Shutdown
Mode N/A MAP 90.0°C N/A 1200 rpm N/A N/A N/A N/A N/A 0.5 Kpa 90.0°C
Maximum
Trip Point
for Shutdown
56
Marine Engine Customer Programmable Options
(Using Service Tools)
High Low
Voltage Temperature Temperature Overspeed Restriction Altitude Temperature Differential Differential Pressure Temperature Oil Pressure
Warning Default Default Default Default Default Optional Default Default Default Default Default Default
Derate N/A Optional N/A N/A Optional Default Optional N/A N/A N/A Optional N/A
Shutdown N/A Default N/A Optional N/A N/A N/A N/A N/A Optional Optional Optional
Default Delay
Time for
Warning
Mode 10 seconds 5 seconds 5 seconds 0 seconds 5 seconds N/A 5 seconds 5 seconds 5 seconds 3 seconds 5 seconds 4 seconds
Default Trip
Point for
Warning 1.15 x See Chart
Mode 20.0 volts 102.0°C 80.0°C rated speed 7 Kpa N/A from 2T spec 105 Kpa 70 Kpa 2.0 Kpa 102.0 Kpa Below
Default Delay
Time for Start
Derate
Mode N/A 30 seconds N/A N/A 5 seconds N/A 5 seconds N/A N/A N/A N/A N/A
Default Step
Delay Time
for Derate
Mode N/A N/A N/A N/A N/A N/A 15 seconds N/A N/A N/A N/A N/A
Default Trip
Point for
Derate Mode N/A 105.0°C N/A N/A 7 Kpa from 2T spec from 2T spec N/A N/A 6.0 Kpa 125°C N/A
Default Delay
Time for
Shutdown
Mode N/A 5 seconds N/A 0 seconds N/A N/A N/A N/A N/A 3 seconds 5 seconds 9 seconds
Default Trip
Point for
Shutdown 1.15 x
Mode N/A 107.0°C N/A rated rpm N/A N/A N/A N/A N/A 3.5 Kpa 107.0°C MAP
57
Marine Engine Factory Programmable Options
(Section 1)
High Low
Warning Default Default Default Default Optional Default Optional Default Default Default Default Default
Derate N/A N/A Optional N/A N/A Optional Default Optional N/A N/A N/A Optional
Shutdown N/A Optional Optional N/A Default N/A N/A N/A N/A N/A Optional Optional
Startup
Delay Time N/A 10 seconds N/A 10 minutes N/A N/A N/A N/A N/A N/A N/A N/A
Time to Reach
Maximum
Security Level 1 3 1 1 3 1 3 3 1 1 3 1
Maximum
Derate
Percent or
Maximum
Maximum
Derate
58
Marine Engine Factory Programmable Options
(Section 2)
High Low
Default Delay
Time for
Warning
Minimum
Delay Time
for Warning
Maximum
Delay Time
for Warning
Default Trip
Point for
Warning 1.18 x
Minimum
Trip Point
for Warning
Maximum
Trip Point
for Warning
Default Delay
Time for
Start Derate
Minimum
Delay Time
for Start
Maximum
Delay Time
for Start
Default
Step Delay
Time for
Minimum
Step Delay
Time for
Maximum
Step Delay
Time for
Default
Trip Point for
Minimum
Trip Point for
Maximum
Trip Point for
Default
Delay Time
for Shutdown
Minimum
Delay Time
for Shutdown
Maximum
Delay Time
for Shutdown
Default
Trip Point
for Shutdown 1.18 x
Mode N/A MAP 107.0°C N/A rated rpm N/A N/A N/A N/A N/A 3.5 Kpa 107.0 C
Minimum
Trip Point
for Shutdown
Maximum
Trip Point
for Shutdown
59
Monitoring System Features and Capabilities
Pilot House Panels for 3500B Marine Engines will include various configurations of
the following components:
Control Groups Display fault lights and digital reading of gauges, engine speed, and analog
Display of various performance and operation parameters
Toggle switch Control digital display of analog gauge readings
Engine Control Module Green is on while both ECMs are operational, amber comes on if primary
monitoring lamps ECM fails
Emergency stop switch Protected against accidental actuation by a protective ring
Dimmer switch Control the amber nightvision lamps inside the control group
Start-stop switch Starts and stops the engine remotely
These panels may be installed a maximum of 100 ft from the engine.

Pilot House Instrument Panels
Part Number Picture of Panel
123-8212
Premium Panel
123-8210
Basic Panel
123-8211
Basic Panel
with Switches
60
Cutouts for various components of Pilot House Panels
122-0132 Pilot House Panel

(Guages and LED Parameters)
1 - System Shutdown
2 - Hi JW Temp
3 - Oil Pres
4 - Hi Exh Manifold Temp
5 - Engine Coolant Level
6 - Fuel Pres
7 - Mar Gear Oil Temp
8 - Mar Gear Oil Pres
9 - System Voltage
10 - Diagnostic Indicator
A - Oil Pres E - LH Exh Manifold Temp

B - Coolant Temp F - RH Exh Manifold Temp
C - Mar Gear Oil Pres G - Boost Pres
D - Mar Gear Oil Temp H - Aftercooler Temp
61
Marine Engine Monitoring System Defaults
Service Tool Customer Programmable Options
High Low
Warning Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional
Derate N/A N/A Optional N/A N/A Optional Optional Optional N/A N/A Optional Optional
Shutdown N/A N/A N/A N/A Optional N/A N/A N/A N/A N/A N/A N/A
Default Delay
Time for
Warning
Default Trip
Point for
Warning 1.18 x
Default Delay
Time for Start
Derate
Mode N/A N/A 30 seconds N/A N/A 5 seconds N/A 5 seconds N/A N/A N/A N/A
Default Step
Delay Time
for Derate
Mode N/A N/A N/A N/A N/A N/A N/A 15 seconds N/A N/A N/A N/A
Default Trip
Point for
Derate Mode N/A N/A 107.0°C N/A N/A 7 Kpa from 2T spec from 2T spec N/A N/A 6.0 Kpa 107.0°C
Default Delay
Time for
Shutdown
Default Trip
Point for
Shutdown 1.18 x
62
Application Builder Factory Programmable System Defaults
High Low
Off Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled
Warning Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled Enabled
Derate N/A N/A Enabled N/A N/A Enabled Enabled Enabled N/A N/A Enabled Enabled
Shutdown N/A N/A N/A N/A Enabled N/A N/A N/A N/A N/A N/A N/A
Startup Delay
Time to Reach
Maximum
Derate N/A 10 seconds N/A 10 minutes N/A N/A N/A N/A N/A N/A N/A N/A
Reach
Maximum
Security Level 1 3 3 3 3 3 3 3 1 1 3 3
Maximum
Derate
Percent or
Maximum
Maximum
Derate
63
Application Builder Factory Programmable Parameters
High Low
Default Delay
Time for
Warning
Minimum
Delay Time
for Warning
Maximum
Delay Time
for Warning
Default Trip
Point for
Warning 1.18 x
Minimum
Trip Point
for Warning
Maximum
Trip Point
for Warning
Default Delay
Time for
Start Derate
Minimum
Delay Time
for Start
Maximum
Delay Time
for Start
Default
Step Delay
Time for
Minimum
Step Delay
Time for
Maximum
Step Delay
Time for
Default
Trip Point for
Minimum
Trip Point for
Maximum
Trip Point for
Default
Delay Time
for Shutdown
Minimum
Delay Time
for Shutdown
Maximum
Delay Time
for Shutdown
Default
Trip Point
for Shutdown 1.18 x
Minimum
Trip Point
for Shutdown
Maximum
Trip Point
for Shutdown
64
3500B Electronic Instrument Panel
Instruments There is an option to add a third gauge cluster

There are are a minimum of two standard module. The third gauge cluster module for EPG
configurations of the 3500B instrument panels. applications displays:
The standby EPG package with switchgear • Inlet air pressure (boost)
conversion will have two modules as standard, • Separate circuit aftercooler coolant temperature
while the other EPG packages with switchgear
• Engine oil temperature
conversion and all other engine applications will
have three modules as standard with the option to • Inlet air temperature
add a fourth module and a pyrometer. The two
modules included with every instrument box are The third gauge cluster module for marine
the main display module and gauge cluster applications displays:
module. The main display module controls all the • Inlet air pressure (boost)
instruments and gauge cluster module displays: • Separate circuit aftercooler coolant temperature
• Engine oil pressure • Marine gear oil temperature
• Engine coolant temperature • Marine gear oil pressure
• System voltage
• Engine fuel pressure
Applications other than standby EPG have a

second gauge cluster module which displays:
• Right hand and left hand air inlet restriction
• Right hand and left hand exhaust temperature
• Fuel filter differential pressure
• Oil filter differential pressure
65
Engine Control Switch 1. The CLEAR/MODE switch is used to move
The engine control switch has four positions and is between the five available modes of operation
used to control the engine. and to clear information that is currently being
displayed on the main display module. The
1. The OFF/RESET position removes power from main display module will cycle through the five
the engine. different modes of operation when the
2. The AUTO position powers up the engine CLEAR/MODE switch is held down in the
control module (ECM) and allows the ECM to mode position. When the desired mode is
monitor the status of a remote start / stop reached, release the switch and the main
switch. Note: The customer remote start/stop display module will remain in that mode of
switch, if equipped, is a switch that can be operation until a different switch input is
wired into the system through the customer received. If the information that is currently
connector “C” to provide a method to remotely being displayed by the main display module is
start and stop the engine. When the engine no longer needed and the information is to be
control switch is in the AUTO position, a removed from memory, the displayed
remote switch can be used to place the engine in information can be cleared by holding the
three different states. The remote OFF position CLEAR/MODE switch up in the clear position
leaves the ECM powered up. The ECM is in a for approximately one second until the
power conserving mode where there is reduced information disappears from the main
power usage. The remote COOLDOWN/STOP display module.
position places the engine in a cooldown mode 2. The SCROLL switch is used to scroll through
(if programmed to cooldown) and then stops the the different parameter information that is
engine. The remote START/RUN position available in a single mode. The main display
starts the engine cycle crank sequence and module will scroll through the parameter
allow the engine to continue to run once it display information that is available in the
is started. active mode when the SCROLL switch is held
3. The MANUAL/START position starts the in the up position. If a continuous display of a
engine cycle crank sequence and allow the parameter is desired, hold the SCROLL switch
engine to continue to run once it is started. in the scroll position until the desired
parameter information is displayed. Release
4. The STOP position places the engine in a the SCROLL switch when the desired
cooldown mode (if programmed to cooldown) parameter information is displayed. The
and then shuts off the engine. parameter information will be displayed until
the main display module receives a different
Emergency Stop Push Button
input.
The emergency stop push button is used to bring
the engine to a quick stop during emergency 3. The LH/RH switch is used to display both the
situations. The emergency stop push button right and left hand parameter information on a
removes power from the ECM and activates the single gauge. Instrument boxes that have a
air shutoffs (if installed). second gauge cluster module (two gauges that
display air inlet restriction pressure and
Note: The customer remote shutdown switch, if exhaust temperature) can show both right hand
equipped, is a switch that can be wired into the and left hand values for the engine. While
system through customer connection “C”. This displaying parameter information for one or the
switch will disable fuel injection and activate the other of these parameters, the right hand and
air shutoffs (if equipped). left hand switch can be toggled back and forth
so that all of the information can be displayed.
Main Display Module Control Switches
The electronic instrument panel houses three
switches that are used to interface with the main
display module.
66
Alarm Marine applications have these additional circuit
The alarm is activated by the main display breakers.
module. The alarm is turned on anytime there is a • Customer Power Circuit
system alarm, a parameter out of range, or there • Control Switch Circuit
is an active diagnostic condition.
• Secondary ECM Circuit
Alarm Silence Switch Customer Interface Connectors
The alarm silence switch is a push button switch There are two customer interface connectors
that allows the operator to turn off the alarm once located on the bottom of the electronic instrument
the alarm has sounded. Activating the alarm panel. The customer connector “D” (24 Pin
silence switch will silence the alarm for five Connector) provides access to the battery ground,
minutes. After the the five minute period, if the switched battery positive, and unswitched batter
conditions that initiated the alarm have not been positive. For marine applications, this connector
corrected, the alarm will sound again. also provides (+) battery and (-) battery access for
the throttle sensor (if equipped), secondary ECM
Circuit Breakers and Wiring ready lamp, and secondary ECM active lamp.
Inside the electronic instrument panel are
numerous circuit breakers to protect the electrical
system and wiring for the control system. The
following circuits are protected by circuit breakers.
• Starter/Emergency Stop Circuit
• Battery Power Circuit
• Relay Circuit
• Starter Relay Circuit
• ECM Circuit
• SEMS Circuit
• Alternator Circuit (an attachment)
67
The customer connector “C” (40 pin connector) remote emergency stop switch, inlet air
provides access to all customer attachments and temperature, and engine oil temperature.
system enhancements. Attachments that interface Attachments that interface through this connector
through this connector for EPG applications for marine application include: marine gear oil
include: speed adjust potentiometer (when not temperature, marine gear oil pressure, fuel level
using the Woodward Load Share Module), fuel switch, coolant level switch, customer remote
level switch, charger fault, coolant level switch, start/stop switch, and customer remote emergency
customer remote start/stop switch, customer stop switch.
EPG Applications - Customer Connector “D”

Pin Number Function Type
1-16 Uncommitted Uncommitted
17 Ground Battery (-)
21-24 Uncommitted Uncommitted
Marine Applications - Customer Connector “D”

Pin Number Function Type
1 Throttle Synchronization Switch Battery (+) Switched
2 Throttle Synchronization Switch Battery (+) Switched
3 Port Throttle Position Sensor Battery (+) Switched
4 Starboard Throttle Position Sensor Battery (+) Switched
5 Secondary ECM Ready Lamp Battery (+) Switched
6 Secondary ECM Active Lamp Battery (+) Switched
7 Uncommitted Battery (+) Unswitched
13 Throttle Synchronization Switch Battery (-)
14 Throttle Synchronization Switch Battery (-)
15 Port Throttle Position Sensor Battery (-)
16 Starboard Throttle Position Sensor Battery (-)
17 Fuel Level Switch Battery (-)
18 Transmission Oil Pressure Sensor Battery (-)
19 Transmission Oil Temperature Sensor Battery (-)
20 Coolant Level Sensor Battery (-)
21 Uncommitted Battery (-)
68
EPG Applications - Customer Connector “C”
1-13 Uncommitted
14 Gen Set On Line
15 Uncommitted
16 Battery Charger Fault
17 Uncommitted
18 Fuel Level Switch
19 Digital Return (From Woodward Load Share Module Pin 20)
20 Digital Return (Remote Customer Shutdown Switch)
21 Digital Return (Remote Start / Stop Switch)
22 Uncommitted
23 Uncommitted
24 Uncommitted
25 Coolant Level Sensor
26 Uncommitted
27 Air Inlet Temperature Sensor
28 Coolant Level Sensor (Signal)
29 Remote Start / Stop Switch
35 Engine Oil Temperature Sensor
36 Pulse Width Modulated Signal (from Woodward Load Share Module Pin 19)
37 Speed Adjust Potentiometer (Speed Control Brick)
40 Uncommitted
69
Marine Applications - Customer Connector “C”
1 Throttle Synchronization Switch
2 Throttle Synchronization Switch
3 Port Throttle Position Sensor (Signal)
4 Starboard Throttle Position Sensor (Signal)
5 Secondary Engine Control Module Ready Lamp
6 Secondary Engine Control Module Active Lamp
7 Connect to Starboard Engine Customer Connector Pin 7
11 Cat Data Link (-)
12 Cat Data Link (+)
13 Shutdown Notify Relay (common)
14 Uncommitted
15 Shutdown Notify relay (Normally Closed)
16 Uncommitted
17 Shutdown Notify relay (Normally Closed)
18 Fuel Level Switch
19 Digital Return (Remote Customer Shutdown Switch)
20 Digital Return (Remote Start / Stop Switch)
21 Digital Return
22 Uncommitted
23 Transmission Oil Pressure Sensor (Voltage Supply)
24 Transmission Oil Temperature Sensor (Voltage Supply)
26 Transmission Oil Pressure Sensor (Signal)
27 Transmission Oil Temperature Sensor (Signal)
33 Remote Customer Shutdown Switch
34 Remote Customer Shutdown Switch
35 Engine Oil Temperature Sensor
36 Uncommitted
37 Uncommitted
38 Uncommitted
39 Uncommitted
40 Uncommitted
70
Internal Instrument Panel Switches The HIGH/LOW SWITCH allows the operator of
Inside the electronic instrument panel are three an EPG engine to hold the engine speed at the
switches that are located in the upper left corner. programmed low idle setting. When the high/low
For EPG applications, the switches are used for: switch is activated, the engine will remain at the
low idle setting. If the high/low switch is de-
• Manual starter crank switch activated, the engine will proceed to the high idle
• Overspeed verify switch setting. The high/low switch is intended to be used
• Hi / low idle switch for troubleshooting and any time that it is desired
to keep the engine at low idle.
For marine application, the switches are used for:
The PRELUBE OVERRIDE SWITCH allows the
• Manual starter crank switch operator of a marine engine to override the
• Overspeed verify switch prelube pump sequence at the beginning of the
• Prelube override switch cycle crank sequence during engine start-up (if
there is an attached prelube pump as part of the
Note: Prelube override switch is present only if engine system). When the prelube override switch
the prelube pump attachment is part of the engine is activated, the ECM will not initiate an engine
package. prelube prior to cranking the engine (the ECM
will immediately begin to crank the engine
The MANUAL STARTER CRANK SWITCH without prelubing). The prelube override switch is
allows the operator to crank the engine using the intended to be used for troubleshooting and to
engine starters and overriding any other control provide for immediate engine starting during
or protection systems. Therefore, the starters can emergency situations.
be engaged even when the engine control switch is
in the “OFF” position or when the ECM has For additional information on the Electronic
completed the cycle crank sequence. The manual Instrument Panel, see “Service Manual -
starter crank switch is intended to be used for 3500B Electronic Instrument Panel”,
system troubleshooting and engine maintenance. Form Number SENR6587 dated July 1995.
The manual starter crank switch should not be
used for normal operation of the engine.
The OVERSPEED VERIFY SWITCH allows the

operator to verify that the overspeed protection
system is working as desired. When the switch is
activated, the ECM will perform an engine
overspeed shutdown (if the Engine Monitoring
System is programmed for this action) at 75% of
the engine overspeed trip point. The overspeed
verify switch is intended to be used for
troubleshooting and verification of engine
protection systems.
71
3500 Caterpillar Electronic Technician
Introduction
Caterpillar Electronic Technician (ET) is a software program that will help find problems quickly and
analyze how to correct them. ET provides you with the capability to access and program the Electronic
Control Module (ECM) from a personal computer. The functionality is similar to the Caterpillar
Electronic Control Analyzer Program (ECAP) tool.
How it works
With ET you can display the status of a group of • View and clear logged diagnostics
parameters (temperatures, pressures, etc.) • View events where irregularities occurred and
simultaneously, view and clear active and logged where logged by the ECM
diagnostics, or display the current configuration of
• Perform diagnostic tests
an ECM. These and many other tasks critical to
your job can be performed with ET. • Perform calibrations
• Retrieve engine totals for fuel used, miles
A graphical interface make this Microsoft® traveled, etc.
Windows™ based software quick to learn and easy
• Included is Caterpillar Flash Memory Software
to use. The version and identification of your ECM
used for uploading new Personality Module data
is automatically retrieved by ET, and displayed on
to the ECM
summary screen when you start the program.
Diagnostic tests and calibrations can also be • Works with Caterpillar Common Services
performed with the software. You’ll find ET much Modules
easier to use than the ECAP tool. • An on-line help system is available. For
additional help, contact the PC Hotline:
Features USA and Canada _ 1-800-843-7237
• Display parameter status Other Countries _ 309-674-5290
• View active diagnostics Fax: 1-309 672-1403
E-Mail: _ THEPCDR ADCCHOST
72
PC Requirements Wiring (required to install the engines)
Minimum Requirements
• Acceptable Wire Types - Three conductor,
IBM PC compatible with 386 25 MHz SL or SXL 16 gauge, shielded cable (grounded at the end
processor furthest from the engine) are required for
• 4 Mb of RAM throttle signal connections.
• 10 Mb of available hard disk space • “Twisted Pair” (not less than 1 turn per inch),
• 3.5 in. 1.44 Mb diskette Drive 16 gauge wire must be used for all “DataLink”
• VGA monitor or display connections. All other customer connections
may be made with 16 gauge.
• PC or MS DOS® 5.0 or greater
• Connection Practices - Deutsch connectors are
• Microsoft Windows version 3.1 the approved method of making connections
• RS232 port not used by mouse or printer (See tool list)
Recommended Portable Unit • Connections paralleling the Family of B
• IBM PC compatible with 486 33 MHz SL Generator sets with Cummins Generators sets
or greater are practical. Special modifications are required
to connect to Barber Coleman ILS module.
• 16 Mb of RAM
• 200 Mb of available hard disk space 3500B EPG Diesel Electronic
• 3.5 in. 1.44 Mb diskette Drive Service Tools
• Super VGA monitor or display The Caterpillar Service Tools for the 3500B EPG
• OS/2 version 2.1 Diesel System are designed to help the service
• PC or MS DOS® 6.2 or greater technician analyze and locate problems within the
system. Their use is required in order to perform
• Microsoft Windows version 3.1
sensor calibrations and to read or change
• RS232 port with high speed UART chip programmable engine parameters.
• Pointing device or mouse
Two Service tools can be used with the 3500B
Other Requirements EPG Diesel engine. The Electronic Technician
(ET) or the Electronic Control Analyzer and
• 7X1700 Communications Adapter
Programmer (ECAP). With either ET or ECAP, a
• NEXG4523 program module (Software for Communication Adapter tool is required to
7X1700 communications adapter version 1.2 communicate with the 3500B Electronic Control
• 7X1688 RS232 cable Module (ECM). ET is the preferred tool due to its
increased functionality, however, the ECAP can be
used to perform basic troubleshooting.
73
ET consists of an IBM compatible computer The following table outlines the tools and cables
(laptop) and software programs. The software needed to use ET to service the 3500B EPG Diesel
programs allow the laptop to program ECM engine:
parameters, read and display sensor values
and switches, perform diagnostic test and
calibrate sensors.

The following Components are required to use Caterpillar Electronic Technician (ET)
1
None IBM PC Compatible - Minimum of 386 (25 mHz)
1
JERD 2124 Single User License for ET version 1.4 (Main ET Program) (Min)
1
JERD2129 Data subscription for all engines and machines.
(Allows ET to communicate with 3500B engines.)
3
7X1700 Communication Adapter Group for use between ET Tool and ECM.
7X1571 Fuse, 7X1569 Fuse, NEEG2464m and SEHS9264
2
NEXG4523 SPM for 7X1700 Communication Adapter Group.
7X1688 Connector Cable (CA to PC) Connects PC (laptop) to Communication Adapter.
7X1570 Connector Cable (CA to ECM) Connects 3500B EPG Diesel ECM to Communication
Adapter tool.
7X1412 Connector Cable - (CA to ECM) ATA Cable connection.

1
Contact the PC hotline at 1-800-THE-PCDR (843-7237) for more information.
2
This is a subscription, since it is anticipated that it will be changing at regular intervals.
3
Refer to Tool Operating Manual SEHS9264, Installation and Use of the 7X1701 Communication Adapter Tool.
74
The following Components are required in addition to an ECAP or CAT ET tool:
4 mm Allen Wrench
2.5 mm Allen Wrench
6V7070 Heavy Duty Digital Multimeter Diesel Multimeter

6V7800 or
9U7330
9U7250 Deutsch DT Connector Repair Kit includes 1U5804 Crimping Tool.

- or -
9U7246 Deutsch DT Connector Repair Kit without Crimping Tool.
7X1710 Signal Reading Probe
6V2197 Timing Calibrating Tools

6V3093 CV2197 Magnetic Pick-up with 6V3093 Adapter sleeve, and 7X1695 Cable.
7V1695
Other Special Tools include those needed to measure pressure and/or temperatures. The following tools are
recommended but are not required:
Optional 3500B EPG Diesel Electronic Service Tools

4
1U5470 Engine Pressure Group includes the following:
8T0839 Differential Pressure Gauge 8TO846 Pressure Gauge
8T0848 Pressure Gauge (3)
1U5469 Pressure Gauge
5
6V9130 Temperature Adapter Group
6
1U6661 Pop (Injector) Tester Group
9U6143 Power Supply Adapter
4C4911 Battery Load Tester

7
8C9700 Rechargeable Portable Printer Prints Parameters, sensor readings, etc,
8
7X11800 Internal Expansion Board for the ECAP. Permits the expansion of the ECAP
capabilities by providing space for more SPM within the ECAP.
4
The 6V9450 Engine Pressure Group may be used instead. Refer to SEHS8524.
5
Refer To Special Instructions SEHS8382.
6
Refer To Special Instructions SEHS8867.
7
Refer To Special Instructions SEHS8740, Using the 8C9700 Rechargeable Portable Printer.
8
Refer to Operating Manual SEHS8834, Installing the 7X1180 Internal Expansion Board in the 8T8697 ECAP Service Tool.
Two short jumper wires will be needed to check continuity of some wiring harness circuits. The jumper
wires are used to short (connect) two adjacent pins or sockets together in a connector.
A long extension wire may be needed to check continuity of some wiring harness circuits.
75
Electrical Installation
Tools and Materials
Part Number Qty Description
8T-8697 1 Electronic Control Analyzer Programmer (ECAP)
NEXG-4521 1 Service Program Module for ECAP

Latest Available Version
NEXG-4523 1 Service Program Module for Communication Adapter

7X-1701 1 Communications Adapter
7X-1180 1 ECAP Internal Expansion Board
(Necessary only if all expansion slots are full with boards for other-than-3500 engines)
7X-1703 1 ECAP Mounting Adapter for Communications Adapter

7X-1570 1 Communications Adapter Cable
(Replaces 7X-1420 with improved ECAP)
7X-1695 1 Timing Probe Cable

6V-2197 1 Timing Probe Magnetic Pickup
6V-3093 1 Timing Probe Adapter Sleeve
8C-9801 1 PWM Signal Adapter Group
7X-1710 1 Signal Reading Probe Group (Red and Black)
4C-3406 1 Deutsch HD10 Connector Repair Kit
1U-5804 1 Deutsch Connector Crimp Tool
9U-7246 1 Deutsch Connector Kit (includes pins)
8T-5318 15 Per Deutsch Connector Pin Remover
Eng (Consumable Tool)
6V-7070 1 Caterpillar Multimeter or

9U-7330 1 Fluke 87 Multimeter
7X-6370 1 T-Harness for 3 pin Deutsch
76
Useful Tools
For Customers
Part Number Qty Description
8T-8697 1 Electronic Control Analyzer Programmer (ECAP)
NEXG-4521 1 Service Program Module for ECAP

Latest Available Version
NEXG-4523 1 Service Program Module for Communication Adapter

7X-1701 1 Communications Adapter
(Replaces 7X-1420 with improved ECAP)
7X-1695 1 Timing Probe Cable

6V-2197 1 Timing Probe Magnetic Pickup
6V-7070 1 Caterpillar Multimeter or
9U-7330 1 Fluke 87 Multimeter
1U-5804 1 Deutsch Connector Crimp Tool
9U-7246 1 Deutsch Connector Kit (includes pins)
8T-5318 15 Per Deutsch Connector Pin Remover
Eng (Consumable Tool)
77
Programmable Relay Operation Summary
Control Module Every relay output or designated LED can be
controlled by any single input. The logic level
Description relationship between input and output is
programmable. A one second debounce is
The Programmable Relay Control Module (PRCM)
continuously active for all inputs. The maximum
provides a method of opening or closing relay
response time from input to output is 2 seconds.
contacts based on any parameter that is is
The display organization follows that of the
available on the Cat Datalink. It can also be
standard Generator Set Controller.
driven by a number of other switch closures, such
as a customer-supplied level, pressure or The user programs an output using a specified
temperature switch. Any warning, derate, display. The user:
shutdown, or switch closure / opening can be • Selects the output to be programmed.
annunciated. The unit is completely
programmable as to what relay is tied to each • Selects the input to control the output.
parameter and whether the relay is normally open • Selects the logical relationship between the
or normally closed. There are nine relays in the output and the input.
PRCM. There are also six switch inputs available The yellow LED on the PRCM display indicates
to drive relays. There are six light emitting diodes predefined fault conditions with the PRCM. Loss
(LED) on the face of the PRCM that can also be of discrete or data link inputs will cause related
programmed to light-up based on a system relay outputs to remain in the state required by
parameter. There is the option to expand to a total the last valid input state.
of twenty five relays by adding two customer
interface modules (CIM) and two relay boards.
The PRCM must be located within 100 ft. of the
engine. The CIM's and the relay boards may be
located up to 1000 ft. from the PRCM. A picture of
the PRCM is below:
78
Operation Restrictions Electronic Interfaces (Preliminary)
The PRCM cannot inform other modules on the Output Relays
data link of input or output status
7 On-board Relays
The PRCM does not latch outputs based on input 7 On-board Display Indicator LEDs
conditions. If a latching function is necessary, the 2 CIMs with 9 relays each
control broadcasting the parameters must latch
the parameter being received and used by the Discrete Inputs
PRCM. 8 Generic Discrete Switch Inputs
Only one PRCM is allowed on a single Cat Data

Link.
ADEM Parameters through Cat Data Link
Active Fault Present Aftercooler Temperature Warning

ECM Voltage Warning Injection Disabled
Engine Jacket Water High Temperature Warning Overcrank
Engine Jacket Water Low Temperature Warning Air Shut-off Relay Active
Overspeed Warning Start Motor Relay Active
Air Inlet Restriction Warning High Engine Oil Temperature Warning
Exhaust Temperature Warning High Inlet Air Temperature Warning
Oil Filter Differential Pressure Warning Low Coolant Level Warning
Fuel Filter Differential Pressure Warning Low Fuel Level Warning
Crankcase Pressure Warning Battery Charger Fault Warning
Engine Speed above 50 RPM Engine At or Above 100% Load Factor
(i.e. engine running) (i.e. in rack limit)
System not in Auto
Shutdown Resulting From: Derate Resulting From:

• Engine Oil Pressure • Altitude
• Engine Jacket Water Temperature • Engine Oil Pressure
• Overspeed • Engine Jacket Water Temperature
• Crankcase Pressure • Air Inlet Restriction
• Aftercooler Temperature • Exhaust Temperature
• Crankcase Pressure
• Aftercooler Temperature
79
If the engine is installed at high altitude and repeated notification of high altitude derate is undesirable,
the notification of altitude derate may be disabled.
Availability
October 1995
Physical Properties English Units Metric Units
Weight lbs kg
Temperatures:
Maximum Storage Temperature +185°F +85°C
Minimum Storage Temperature -40°F -40°C
Maximum Operating Temperature +158°F +70°C
Minimum Operating Temperature -40°F -40°C
Serial Number • The cable connected to the CAT Data Link

Each PRCM has a serial number on the bottom of (designated CDL+ and CDL-) must be 16 AWG,
the flange. It is a five (5) digit number preceded by shielded twisted pair cable. Use Belden® 8719
the letters “SN”. The Caterpillar Part number will (Caterpillar part number 123-2376) or
be on the same flange. It is a seven (7) digit equivalent.
number in the following format: “XXX-XXXX”. • Maximum CAT Data Link cable and power
connections ( B+ and B-) wire length is 100 feet.
Wiring Diagram
No terminations or splices allowed on the
Wire and Cable General Specifications above wires, except as noted in the
• The wires connected to the PRCM power connection diagrams.
connections (designated B+ and B-) must be at
least 16 AWG.
Parameter Being Nominal Total Nominal Nominal Total Nominal

Measured Capacitance per Capacitance Resistance per ft Resistance (1500 ft)
ft (m) (1500 ft) (m) @ 20°C @ 20°C
Conductor to 23 µF (75 pF) 0.035 µF
Conductor
Conductor to 44 µF (144 pF) 0.066 µF
Shield
Single conductor 4.27 milliOhms 6.41 Ohms
series resistance (14.0 milliOhms)
(16 AWG,
19/29 stranding)
80
PRCM Mounting Dimensions
(mm)
Mounting Notes Onboard Discrete Input Electrical

The PRCM is intended to be located on a desk or Requirements
shelf. Do not mount the PRCM on the engine. Each switch input must be pulled to the ground of
the PRCM to activate. The device pulling a switch
Power Requirements input to ground must conduct 5 mA of current.
The battery voltage input requirements are from PULLING AN INPUT TO GROUND will indicate
15 volts to 45 volts DC. The relay coils draw to the software that the input is ACTIVE.
about 20 mA at 24 VDC. Three relays provide
normally open and normally closed contacts. Four Additional Information:
relays provide normally open contacts only. The Guidance on cables, initialization procedures,
relay contacts are silver flashed and rated for 10 interconnection of multiple units, software for use
amp at 28 VDC. The relays are fuse protected. with the PRCM, and Baud rate are not available
at time of publication.
Caution: Multiple gen sets MUST share a
common ground (Battery -). Multiple gen sets must Part Numbers
NOT share a common Battery + to avoid battery Programmable Relay Control 123-6008
power-sharing between units. Module
Additional Relay Driver 123-7450

Relay Board 9Y-6497
81
Customer Communications
Module
Definition • Cat supplied “basic” PC software program along
The Customer Communications Module (CCM) with instructions for customer written
provides a two-way communication link between “customer software”
the engine and the operator of a personal • Cooldown timer override
computer, programmable logic controller, or other • Software can be easily upgraded -
device with a RS-232C port. The operator is “flash memory”
thereby able to remotely control, monitor, and
• Programmable baud rate and data format
program an engine in much the same way an
operator would do from the engine itself. Features • Three levels of password security
of the CCM include: • Activate circuit breaker shunt trip
The connection can either be directly through the
• Remote monitoring of all “real time” engine and
CCM or remotely through a pair of modems.
generator parameters
Software for control by a personal computer is
• Remote monitoring of all alarms, shutdowns, available from Caterpillar (see Owners Manual
and diagnostic tests SEBU6874 for more information). The data
• Remote control of fault relays along with the available from the CCM is only that which is on
low/ high idle relay the Cat DataLink.
82
Physical Properties English Units Metric Units
Weight 1.1 lbs 0.5 kg

Length 5.7 in 145 mm
Width 5.9 in 149 mm
Height 2.9 in 73 mm
Minimum recommended baud rate 9,600
Temperatures:
Maximum Storage Temperature +185°F +85°C
Minimum Storage Temperature -40°F -40°C
Maximum Operating Temperature +158°F +70°C
Minimum Operating Temperature -40°F -40°C
Wiring Diagrams
CCM
10A
12 39 +B
F1 B+ Fused
17
Unit 1 -B
+24 B- (low current)
CAT Data Link +
DATA + CDL+
CAT Data Link -

DATA - CDL-
SHEILD
NOTE A
AUX Terminal Strip - located inside EMPC ll panel on

left wall
TS1 Terminal Strip - located in generator housing

12 EMCP ll Genset Control Relay Module terminal
NOTE A: Shield is to be left open at CCM
83
Serial Number • Null modem required for direct connected
Each CCM has a serial number on the bottom of system
the flange. It is a five (5) digit number preceded by No terminations or splices allowed on the above
the letters “SN”. The Caterpillar Part number will wires, except as noted in the connection diagrams.
be on the same flange. It is a seven (7) digit
number in the following format: "XXX-XXXX". Mounting Notes
Wiring Diagram The CCM is intended to be located on a desk or

shelf. Do not mount the CCM on the engine or
Wire and Cable General Specifications within the EMCP-II panel.
• The wires connected to the CCM power Battery Power Requirements
connections (designated B + and B -) must be at
least 16 AWG. The battery voltage input requirements are from
15 to 45 volts DC (24 or 32 volts DC nominal).
• The cable connected to the CAT Data Link Power dissipation between the “Battery +” and the
(designated CDL + and CDL -) must be 16 AWG, “Battery -” is 3.0 W at 24 volts. Caution: Multiple
shielded twisted pair cable. Use Belden 8719 gen sets MUST share a common ground
(Caterpillar part number 123-2376) or (Battery -). Multiple gen sets must NOT share a
equivalent. common Battery + to avoid battery power-sharing
• Maximum 100 feet, including wire runs between between units.
any multiple gen sets.
• Maximum total wire length for the RS-232 cable CCM Battery (Internal)
is 50 feet. It should be standard 25 pin “D” type The CCM contains a battery that supplies power
connector. Cable must include; transmit, for internal memory whenever the CCM power is
received, DTR, DCD and ground conductors turned off.
Parameter Being Nominal Capacitance Total Nominal Nominal resistance Total Nominal
Measured per ft (m) Capacitance per ft (m) @ Resistance (1500 ft)
(1500 ft) 20°C @ 20°C
Conductor to Conductor 23 µF (75 pF) 0.035 F
Conductor to Shield 44 µF (144 pF) 0.066 F
Single conductor series 4.27 milliOhms 6.41 Ohms
resistance (16 AWG, (14.0 milliOhms)
19/29 stranding)
84
Sample PC Software Screen
Monitor Screen
PHASE VOLTS FREQ AMPS
A 400 50.0 1200
SPEED OIL PRESSURE COLANT TEMP BATTERY VOLTAGE ENGINE HOURS
1500 72 KPA 65 DEG C 24 12473
STATUS ALARMS SHUTDOWNS
ECS SWITCH START NOT IN AUTO LOW OIL PRESS.
ELC GOV. RLY LOW OIL PRESS. EMERGENCY STOP
GEN. FAULT GOV. RLY LOW COOLANT TEMP. HIGH COOLANT TEMP.
CRANK TERM RLY HIGH COOLANT TEMP. LOW COOLANT LEVEL
STARTER MTR RLY OVERCRANK
RUN RLY SPARE INPUTS FAULT SHUTDOWN
AIR SHUTOFF RLY SPARE INPUT #1 FAULT ALARM
FUEL CONTROL RLY SPARE INPUT #2 DIAGNOSTIC CODE
SPARE RLY SPARE INPUT #3 OVERSPEED
SPARE OUTOUT
SITE: CCM DEMO ENGINE NO. 1 TIME: 04:12:55 DATE: 03/30/1994
F1-HELP F2-CHANGE AC PHASE F4-CHANGE ENGINE NO. F10-MAIN
Control Screen
RPM EC SWITCH MODE
SELECT STATUS
REMOTE START/STOP STOP
COOLDOWN OVERRIDE OFF
HIGH/LOW IDLE RLY UNPOWERED
GENERATOR FAULT RLY UNPOWERED
REMOTE FAULT RLY UNPOWERED
SPARE OUTPUT UNPOWERED
EMERGENCY STOP UNPOWERED
SITE: CCM DEMO ENGINE NO: 1 TIME: 04:12:55 DATE: 03/30/1994

F1-HELP F2-CHANGE SETTINGS F4-CHANGE ENGINE NO. F10-MAIN
Set-up Screen
CCM/GSC GSC
CONNECTION VERSION
BAUD RATE 9600 GENSET #1 CONNECTED BASIC
PARITY N GENSET #2
DATA BITS 8 GENSET #3
STOP BITS 1 GENSET #4
CONNECTION TYPE DIRECT GENSET #5
GENSET #6
GENSET #7
USER #1 USER #2 USER #3 USER #4 USER #5

1 2 2 2 3
USER #6 USER #7 USER #8 USER #9 USER #10
3 3 3 3 3
SITE: CCM DEMO
F1-HELP F2-PROGRAM CCM F10-MAIN
Additional Information:
See Owners Manual - Customer Communication Module for Electronic Modular
Control Panel II for guidance on use of CCM on generator sets equipped with
EMCP-II.
85
3500B Cooling Systems
There are several new features of the 3500B For the ultimate in engine fuel
cooling systems. 3500B Marine Engines all have efficiency/emissions, the engine's aftercooler
separate cooling circuits for their aftercoolers. circuit is expected to be provided by the customer.
The customer must provide whatever heat
• The heavy weight marine engines have transfer device is most practical to get the lowest
thermostats on the aftercooler circuits, aftercooler water temperature year around. On
controlling the temperature so it never goes some installations this will be a split core radiator,
below 30°C (86°F). They are also designed to a cooling tower, or a spray pond. In other
allow only treated, fresh water through their installations, city water, a well or a submerged
aftercoolers. pipe cooler will be used. In any case, it is the
• The high performance marine engines pump sea customer's responsibility to provide the cooling
water directly through their aftercoolers and do means for the aftercooler circuit, if ultimate
not use thermostats to control the aftercooler engine performance (lowest aftercooler water
water temperature. temperature) is needed.
• The engine’s performance is tied to the
For a more cost effective arrangement, the factory
temperature of the water through the
will provide special radiators with dual inlets and
aftercooler. The cooler that water, within certain
outlets, so both the jacket water and the
limits, the better the fuel efficiency, the
aftercooler water are cooled in the same radiator
emissions, and the life of the engine. This places
core. These radiator arrangements will deliver
a high priority on the proper sizing of the
fairly low aftercooler water temperatures, in all
aftercooler circuit heat transfer device (radiator,
but extreme conditions. That is, when the
heat exchanger or keel cooler). The aftercooler
engine/generator are not running at full load, at
circuit thermostat protects against part load
relatively low ambient air temperatures and if the
problems associated with overcooling.
radiator is oversized. Radiator performance is
• The jacket water heat rejection of the more difficult to forecast when operating in this
3500B Marine Engine no longer includes the mode. It is recommended that radiator
heat rejection of the aftercooler, though the heat performance be obtained from the factory when
rejected by the engine oil cooler is still included. using this cooling strategy, because of the
• The radiator cooled EPG engines deal with the repetitive nature of the calculations:
separate circuits in two ways:
86
Radiator Sizing
Sizing of Cooling systems for 3500B Marine Engines is generally the same as other Caterpillar engines.
There are some Differences, mainly having to do with the separate circuit aftercooling aspect of the
3500B Family of Engines, and they will become immediately obvious from viewing the schematic
drawing below:
3500B Radiator Groups

Part Fan Core Height Width Length Dry Wt Fluid Wet Wt.
Number Dia /Ratio (in) (in) (in) (lb) Cap. (lb)
(US gal)
7C-4501 50” Var. FCR (50-11) 88 54 60 798 23 982
7E-7527 60” Var. FCR (60-13) 93 64 67 1151 29 1296
7E-7528 72” Var. FCR (72-25) 97 92 67 1888 45 2248
124-4620 60” Var. 25CVD 92 64 67 1370 28 1594
124-2629 60” Var. 35CVD 89 81 67 1970 39 2282
9Y-6676 72” Var. 46CV 102 92 68 2450 59 3162
120-9506 72” Var. 46CVD 102 92 68 2450 50 3162
120-9110 84” 0.357 60CVD 119 101 77 3865 73 4449
120-9114 84” 0.422 60CVD 119 101 77 3865 73 4449
120-9504 84” 0.357 72CVD 128 113 77 4200 83 4864
120-9120 84” 0.422 72CVD 128 113 77 4200 83 4864
120-9122 84” 0.357 85CVD 126 135 83 5055 87 5751
120-9124 84” 0.422 85CVD 126 135 83 5055 87 5751
127-1545 60” Var. 25CVD COPON 92 64 67 1370 28 1594
127-1539 60” Var. 35CVD COPON 89 81 67 1970 39 2282
127-1536 72” Var. 46CVD COPON 102 92 68 2450 59 3162
127-1541 84” 0.357 60CVD COPON 119 101 77 3865 73 4449
127-1534 84” 0.422 60CVD COPON 119 101 77 3865 73 4449
Marine Auxiliary have copon coated cores. Conventional Terminology:
CV = Conventional First 2 numbers represent size in square feet, i.e., 46CVD has a 46
CVD = Conventional, Dual Circuit square foot core.
FCR = Folded Core Radiator
Folded Core Technology:
First 2 numbers represent fan size in inches,
Last 2 numbers represent number of core modules, i.e., 72-75 has a
72” fan and 25 core modules.
87
Radiator Sizing Calculation Example
3500B dual circuit - refer to 7C-7500 Sizing Chart
3512 - 1360 EkW @ 1800 rpm, Prime, Low NOx
Find Heat Rejection in TMI:
Data Set A/C Water Temp. Jacket Water Heat Aftercooler Heat
Rejection (Btu/Min) Rejection (BTU/Min)
DM1724 30°C 34,918 25,193

DM1732 60°C 34,918 21,952
DM1740 90°C 34,406 16,890
Add 10%
30°C 38,410 27,712
60°C 38,410 24,147
90°C 37,847 18,579
Ta = Tmc _ (Jacket Water Heat Rejection + Aftercooler Heat Rejection

Effective Heat Load
x 100)
Where:
Ta = Ambient Temperature
For Prime and Continuos, Tmc = 200°F
For Standby, Tmc = 210°F
Effective Heat Load can be found on Radiator Chart (next page)
Correct Ta for Glycol effect (1.8°F/10% Glycol)
and Altitude Effect (0.5%/200 ft - above 600 ft)
and Air-to-Core Temp Rise Effect (See 7C-7500)
The result is the Ambient Capability.
For Radiator Sizing for cooling of jacket water only, use Jacket Water Heater Rejection in place of
(Jacket Water Heat Rejection + Aftercooler Heat Rejection) in the above equation.
For Jacket Water Aftercooled Engines, use Jacket Water Heat Rejection in place of
(Jacket Water Heat Rejection + Aftercooler Heat Rejection) in the above equation.
For Folded Core Radiator Sizing use 7C-7500.
For Aftercooler Temperatures for CVD Radiators at part load or at less than maximum ambient
temperature, consult factory.
88
Effective Heat Load - Radiators
Radiator Fan Drive Engine Fan Speed Effective Fan Air Flow
Ratio Speed (rpm) (rpm) Heat Load Diameter (cfm)
(Btu/min) (in)
25 CVD 0.520 1800 935 43000 60 46800

0.627 1500 940 43000 46800
35 CVD 0.520 1800 936 48000 60 55100
0.627 1500 940 48000 55100
46 CVD 0.428 1800 770 78000 72 82650
0.520 1500 780 79000 84550
60 CVD 0.357 1800 643 97500 84 102125
0.422 1500 642 97500 102125
72 CVD 0.357 1800 643 106500 84 107350
0.422 1500 642 106500 107350
85 CVD 0.357 1800 643 115000 84 112100
0.422 1500 642 115000 112100
89
EPG Engine Cooling Schematic System
(Dual Circuit, Single Core Radiator, with auxiliary source for aftercooler circuit coolant)
The information above is to aid the aftercooler water allows better fuel efficiency and
designer/installer to use the new features of the reduced exhaust emissions. There are schematics
3500B cooling system. The most obvious of the new systems, a table of system volumes,
difference between the B family of engines and sample calculations with tables, and graphs of all
their predecessors is the use of a separate cooling pumps and heat exchangers.
circuit for the engine's aftercoolers. Cooler
90
Marine Engine Cooling Schematic
(Dual Heat Exchanger, with closed circuit of treated water for aftercooler circuit)
Marine Engine Cooling Schematic

(Dual Keel Coolers, with closed circuit of treated water for aftercooler circuit)
91
3500B Marine Engines
Calculated Aftercooler Circuit Volumes
Model Circuit Volume
3508B 5.3 U.S. gal
3512B 6 U.S. gal
3516B 7.4 U.S. gal
Calculations for Sizing Cooling Systems

Chart A: shows all the 3500 heat exchanger Chart C: is for 2 heat exchangers in Series,
performance curves and their usage, including and shows the flow rates to use for calculations,
shell temperature, shell flow and intended circuit. depending on which heat exchanger, engine size,
If your shell temperature and/or flow is expected engine rpm, and pump size are used. Plumbing
to be significantly different than the values used is twice the length of pipe and twice the
published, you will need to generate your own number of elbows shown for Chart B.
performance curves using the Effectiveness Curves
described later. Chart D: is for three (3) exchangers in series
(tube side only, and shows the flow rates to use for
Chart B: shows the flow rates to use for calculations, depending on which heat exchanger,
calculations, depending on which heat exchanger, engine size, engine rpm and pump size are used.
engine size, engine rpm, and pump size are used. Plumbing used is three times the length of pipe
Flows are based on the following heat exchanger and three times the number of elbows shown for
plumbing: Chart B.
If your plumbing is significantly different than Chart E: is for two (2) heat exchangers in
that shown, you will need to determine your flow parallel, and shows the the flow rates to use for
rate by generating a restriction curve for your calculations, depending on which heat exchanger,
plumbing and adding it to the heat exchanger engine size, engine rpm and pump size are used.
restriction curves in section B. The intersection of Plumbing used is twice the length of pipe and
this new curve and the applicable pump curve will twice the number of elbows shown for Chart B.
give the flow rate of your plumbing configuration.
If NONE appears on a chart for the TMI
performance curve, the flow is outside the range
Pipe Size Pipe
(inside dia.) Length No. of 90° of published curves. Curves for these particular
Circuit in. ft. Elbows flows can be generated using the Effectiveness
Curves explained later.
Jacket Water 4 or 5 20 6
1
Shell
Separate After- 3 30 8
Cooler Circuit
Sea Water 3 20 8
Tubes
1Note on Jacket Water Plumbing: Although the Jacket Water pump

inlet and the heat exchanger inlet and outlet are 5 in. ID, 4 in. or
4.5 in. piping may be used for Jacket Water Plumbing if the pipe
length and number of elbows does not exceed those listed. If your
pipe length and number of elbows are more than those listed, use
5 in. pipe. If the pipe length and the number of elbows are
significantly more than those listed, pipe greater than 5 in. may be
needed. Plumbing and heat exchanger restriction shoud never be
restrictive enough to reduce the flow to less than the lowest point
shown on the jacket water pump curve.
92
JWAC Example Next try the medium-sized heat exchanger,
Assumptions: PA2093 - 3512 Marine Propulsion 4W-4642.
Engine - rated 969.5 kW (1300 bhp) at 1800 rpm C From Chart B, shell flow = 400 gpm; the
Intermittent from TMI, TM0051, Jacket Water applicable performance curve is DM2594;
Heat Rejection = 50330 Btu/min Seawater seawater flow is 170 gpm. Using DM2594,
temperature is 30°C (86°F). Good engineering performance is 50,728 Btu/min, also too small.
practice dictates adding 10% safety factor the Next try the largest heat exchanger, 4W-4652.
nominal data: From Chart B, shell flow = 400 gpm; the
50330 Btu/min x 1.1 = 55363 Btu/min applicable performance curve is TM3833;
seawater flow is 170 gpm. Using TM3833,
Start with the smallest heat exchanger - 4W-4632 performance is 60,645 Btu/min. This heat
exchanger is large enough to cool the
From Chart B, shell flow = 400 gpm, and the 55,363 Btu/min rejected by this engine and rating.
applicable performance curve is DM2593. Also Next, make sure the seawater outlet temperature
from Chart B, seawater flow is 170 gpm with the is less than 54.4°C (130°F) to avoid precipitation
standard seawater pump 8N-8466. Using of dissolved salts from the sea water which will
DM2593, it is seen that heat exchanger coat the heat transfer surfaces of the heat
performance for our seawater flow rate and exchanger:
temperature can be read to be 34,900 Btu/min,
∆T = ____________
Heat Rejection (Btu/min) _____
55363
well below the required 55,363 Btu/min. Flow (gpm) x 7.99
= 170 x 7.99 = 40.8°F
Sea water outlet temperature = 86°F +

40.8°F = 126.8°F
93
Chart A
Available Heat Exchanger Performance
TMI # P/N Shell Temp (°F) Shell Flow (gpm) Typical Shell Circuit
DM2593 4W-4632 210 400 JW
TM3968 4W-4632 210 300 JW
DM1290 4W-4632 210 150 90°C SCAC
DM1291 4W-4632 149 150 60°C SCAC
DM1300 4W-4632 106 150 30°C SCAC
DM2594 4W-4642 210 400 JW
TM3969 4W-4642 210 300 JW
DM1292 4W-4642 210 150 90°C SCAC
DM1293 4W-4642 149 150 60°C SCAC
DM1301 4W-4642 106 150 30°C SCAC
TM3833 4W-4652 210 400 JW
DM2595 4W-4652 210 300 JW
DM1294 4W-4652 210 150 90°C SCAC
DM1295 4W-4652 149 150 60°C SCAC
DM2577 4W-4652 106 150 30°C SCAC
For all curves: tube flow range is 55-220 gpm;

tube temperature range 41-140°F.
4W-4632 = 3N-8888 = 3N-8889 = 107-1729
4W-4642 = 3N-8890 = 3N-8891 = 107-1728
4W-4652 = 3N-8892 = 3N-8893 = 107-1730
94
95
96
97
98
Aftercooler Circuit Expansion Tank On electric power generator engines, a vent line is
If the separate circuit aftercooling (SCAC) cooling installed at the factory between the aftercooler
system is a closed system, an expansion tank is front end tank and the upper regulator housing.
required, and should be sized including, the This vent line should be removed if mixing of the
on-engine aftercooler circuit volumes shown. If jacketwater and aftercooler coolants is not
possible, the expansion tank should provide a acceptable. If the vent line is removed, other
shunt line near the aftercooler pump inlet, to help means to vent the aftercooler circuit must be
insure a positive head on the water pump inlet. provided.
The shunt line flow area should be at least 4 times Vent lines should enter the expansion tank below
the area of all vent lines connected to the tank. the normal water level, and contain no air traps.
Aftercooler Circuit Air Venting Jacketwater Shunt Tank Systems
A closed separate circuit aftercooling circuit If a jacketwater shunt tank and air separator are
system must be purged of air during filling. used instead of an engine-mounted expansion
On marine engines, air can be bled out of the tank, the shunt tank must be at a sufficient height
system by removing the plug on the aftercooler to provide enough head for proper air separator
front or rear end tank during filling. A better operation. If the shunt tank is not high enough, an
method would be to install a permanent vent line excess amount of engine outlet water will flow to
from one of the end tanks to the SCAC system the shunt tank through the air separator vent
expansion tank. line, and may result in exceeding the shunt tank
pressure cap limit.
The aftercooler system on seawater aftercooled
(SWAC) marine engines is an open system and
does not need to be vented. The seawater
aftercooling system should never be vented to the
jacketwater system on SWAC engines.
99
100
Separate Circuit Aftercooled Objective: find the smallest pair of heat
(SCAC) Example exchangers that will cool the Jacket Water and
Initial assumptions: cool the Separate Circuit Aftercooler water to
LA-0272 3516B Marine Prop 1491 kW (2000 hp) 60°C, with a seawater temperature of 30°C(86°F).
@ 1800 rpm A-Cont Set for “Best NOx” From
Start with two of the smallest heat exchangers,
TMI, DM1491, @ 30°C SCAC: Jacket Water Heat
4W-4632. The heat exchangers are in series on the
Rejection = 31,790 & Aftercooler Heat Rejection =
seawater (tube) side, and the seawater flow with
21,724 Btu/min and @ 60°C SCAC: Jacket Water
pump 8N-8466 can be found on Chart C to be
Heat Rejection = 33,667 & Aftercooler Heat
150 gpm. First look at the heat exchanger used for
Rejection = 18,028 Btu/min.
the Separate Circuit Aftercooler water. Chart B
Add a 10% safety factor to the nominal data: shows the Separate Circuit Aftercooler flow rate to
30°C: Jacket Water Heat Rejection = 31,790 x 1.1 be 150 gpm. Chart A indicates DM1291 is the
= 34,969 & Aftercooler Heat Rejection = 21,724 x correct heat exchanger performance curve. It is
1.1 = 23,896 Btu/min 60°C: Jacket Water Heat seen that this heat exchanger is capable of only
Rejection = 33,667 x 1.1 = 37,034 & Aftercooler about 17,000 Btu/min, well short of the
Heat Rejection = 18,028 x 1.1 = 19,831 Btu/min 19,831 Btu/min required.
101
Next try two of the medium-size heat exchanger, Next look again at two of the medium-size heat
4W-4642. Chart C shows the seawater flow to be exchanger, 4W-4642.
150 gpm. Chart B shows the SCAC flow to be
150 gpm. Chart A indicates DM1293 is the correct Chart C shows that sea water pump 4W-6674
performance curve. DM1293 shows a capability of gives a tube flow of 155 gpm. Since two of these
20,947 Btu/min, which is enough to cool the heat exchangers provided adequate cooling with a
19,831 Btu/min Separate Circuit Aftercooler heat seawater flow of 150 gpm, they will also be
rejection. To find the sea water temperature into adequate at 155 gpm. All that needs to be done is
the JW heat exchanger, find the temperature rise to check the final sea water outlet temperature
and add it to 86°F: with the higher sea water flow rate. Calculate the
temperature rise across the SCAC heat
∆T = ____________
19831
= 150 x 7.99 = 16.5°F exchanger:
Flow (gpm) x 7.99
∆T = ____________
19831
Seawater outlet temperature = 86°F + Flow (gpm) x 7.99
= 155 x 7.99 = 16.0°F
16.5°F = 102.5°F = JW heat exchanger sea
water inlet temperature Seawater outlet temperature = 86°F + 16°F
= 102°F = JW heat exchanger sea water
From Chart B, JW flow is 400 gpm. From Chart B inlet temperature
or Chart A, DM2594 is the performance curve to
use. DM2594 shows that 4W-4642 is capable of Calculate the final seawater outlet temperature
48,055 Btu/min, which is more than large enough by finding the temperature rise across the JW
to cool the 37,034 Btu/min JW heat rejection. heat exchanger:
∆T (deg F) = ____________
37034
Next make sure the seawater outlet temperature Flow (gpm) x 7.99
= 155 x 7.99 = 29.9°F
does not exceed 130°F. This is necessary to avoid
precipitation of dissolved salts out of the sea water Final seawater outlet temperature = 102°F +
which will plate out on the heat transfer surfaces, 29.9°F = 131.9°F
reducing the heat exchanger performance. Since this seawater temperature is still too high,
∆T (deg F) = ____________
37034
= 150 x 7.99 = 30.9°F the next larger pump, 9Y-5710, needs to be looked
Flow (gpm) x 7.99 at.
Seawater outlet temperature = 102.5°F + Start again with 2 of the smallest heat exchanger,
30.9°F = 133.4°F 4W-4632.
This seawater temperature is over the goal of Chart C shows the seawater pump 9Y-5710 gives
130°F. To avoid loss of performance of the heat a tube flow of 245 gpm. To avoid accelerated tube
exchanger, a different sea water pump with higher erosion because of excessive velocity, flow should
SCAC flow should be used. The higher seawater be kept at 220 gpm or below by adding an orifice
flow may also allow the use of a smaller heat or adjustable valve at the pump outlet. Looking
exchanger. first at the heat exchanger used for the SCAC
Start again with two of the smallest heat water, Chart B again shows the SCAC flow rate to
exchanger, 4W-4632. be 150 gpm, and Chart A shows DM1291 to be the
correct heat exchanger performance curve.
Chart C shows that sea water pump 4W-6674 DM1291 shows the heat rejection capacity to be
gives a tube flow of 160 gpm. First look at the heat 19,900 Btu/min, which is adequate for cooling the
exchanger used for the SCAC water. From Chart required 19,831 Btu/min.
B, SCAC flow rate is 150 gpm. Chart A indicates
DM1291 is the correct heat exchanger
performance curve. It is seen from DM1291 that
this heat exchanger is capable of only about
18,255 Btu/min, well short of the 19,831 Btu/min
required.
102
Next look at the Jacket Water heat exchanger. Looking at Chart C, the JW flow is 300 gpm, and
Calculate the sea water temperature to the JW TM3968 is the correct performance curve. TM3968
heat exchanger: shows that this heat exchanger is capable of
40,380 Btu/min, which is large enough for the
∆T = ____________
19831
Flow (gpm) x 7.99
= 220 x 7.99 = 11.3°F required 37,304 Btu/min. Now check the final sea
water outlet temperature:
Jacket Water heat exchanger seawater
∆T = ____________
37304
inlet temperature = 86°F + 11.3°F = = 220 x 7.99 = 21.2°F
Flow (gpm) x 7.99
97.3°F
Final sea water outlet temperature =
97.3°F + 21.2°F = 118.5°F
103
Sea Water Aftercooled Example Although this rating is 1835 rpm, the 1800 rpm
Initial assumptions: data can be used. If the engine speed is
LA-0597 3512B Marine Prop 1454 kW significantly different than any of the speeds
(1950 bhp) @ 1835 rpm C-Int shown on Charts A-E, the flow rate can be
extrapolated or interpolated using the Pump
From TMI, DM1835 Laws.
Jacket Water Heat Rejection = 31051 Btu/min and Start with the smallest heat exchanger, 4W-4632.
Aftercooler Heat Rejection is 21830 Btu/min
Chart B shows the seawater flow to be 235 gpm,
Add 10% safety factor: which should be limited to 220 gpm. The seawater
flow through the SWAC is 0.6 x 220 = 132 gpm.
Jacket Water Heat Rejection = 1.1 x 31,051 =
34,156 and Aftercooler Heat Rejection 1.1 x 21,838 Seawater temperature rise across the
= 24,022 Btu/min aftercooler is:
∆T = ____________
24022
Seawater temperature is 30°C (86°F). Flow (gpm) x 7.99
= 132 x 7.99 = 22.8°F
In this example, the seawater pump 9Y-5710 is Aftercooler seawater outlet temperature =
connected in series with the aftercooler and the 86°F + 22.8°F = 108.8°F
heat exchanger. There is also a marine gear cooler
connected in parallel with the aftercooler. This If the marine gear is 95% efficient, 5% of the
parallel flow path increases the total flow, but engine bhp has to be removed by the seawater in
since the actual gear cooler water restriction is the form of heat: 0.05 x 1950 = 97.5 hp =
unknown, it is conservative to assume the flow 4,136 Btu/min = Heat Rejection of the
remains the same as without a gear cooler. For Marine Gear.
calculation purposes, it is also conservative to
assume that 40% of the pump flow goes through
the gear cooler. Using these assumptions, the
seawater temperature to the heat exchanger can
be calculated.
104
Seawater flow through the gear cooler is 0.4 x 220 Using Effectiveness Data
= 88 gpm. When any heat exchanger flowrate is outside the
Seawater temperature rise across the gear range of flows in the published heat exchanger
cooler is: data, the effectiveness curves can be used to
determine performance.
∆T = __________ = _____
Heat Rejection 4136
Flow (gpm) x 7.99 88 x 7.99
= 5.9°F
Heat exchanger restriction curves and pump
Gear cooler seawater outlet temperature = performance curves for all available heat
86°F + 5.9°F = 91.9°F exchangers and pumps are attached. A plumbing
Seawater temperature to the heat exchanger is: restriction curve should be derived and added to
the heat exchanger restriction curve before the
(__ ) 108.8 + (__
132 88
) 91.9 + 102.0°F heat exchanger restriction curve is intersected
220 220
with a pump curve to determine flow.
From Chart B, DM2593 is the correct performance Effectiveness is defined as:

curve to use. From DM2593, the heat rejection ∆ T shell
Effectiveness = ___________ = __________
(T shell in - T shell out )
capacity of this heat exchanger is 38,102 Btu/min, (T shell - T tube )
in in (T shell - T tube )
in in
which is large enough for the Jacket Water Heat
Rejection of 34,156 Btu/min. _______________
Since ∆T = Flow
Heat Rejection
x Specific Heat x Density
Next make sure the final seawater temperature
does not exceed 130°F: This equation can be rearranged to give heat
transfer capacity for a given Effectiveness E:
∆T = ____________
34156
Flow (gpm) x 7.99
= 220 x 7.99 = 19.4°F
Heat Rejection = E x Flow x C x (T shell in - T tube in )
Seawater outlet temperature = 102°F +
19.4°F = 121.4°F For this equation, HEAT REJECTION is in
Btu/min, FLOW is in gpm, and Temperatures are
in °F. For sea water, C = 7.99; for a 50/50
freshwater/glycol mixture, C = 7.31; for
freshwater, C = 8.1
Using this equation, a heat exchanger

performance curve can be generated for any
combination of shell flow, tube flow, shell
temperature, and tube temperature.
105
Emissions Data _ ISO 8179-1
ISO Test Cycles
Test Modes and Weighting Factors

Mode Number 1 2 3 4
Cycle E3
1
% of Rated Speed 100 91 80 63
% of Rated Power 100 75 50 25
Weighting Factor 0.2 0.5 0.15 0.15
1
See ISO 8179-1 clause 11.5 and clauses 3.4, 3.5 and 3.6 of this international standard
To comply with ISO 8179-1, an engine must be operated at 100, 75, 50 and 25 percent of rated power,
at the speeds tabulated above, and the resulting emissions levels weighted by the weighting factors
to arrive at the figure displayed in engine specification sheets.
Example:
NOx @ Power @ Speed x Weighting

(g/hp-hr) (%) (%) Factor Calculations
1
7.1 100 100 0.2 7.1 x 0.2 = 1.42
1
6.02 75 91 0.5 6.02 x 0.5 =3.01
1
6.2 50 80 0.15 6.2 x 0.15 = 0.93
1
6.4 25 63 0.15 6.4 x 0.15 = 0.96
1
Spec Sheet NOx Rating 1.42 + 3.01 + 0.93 + 0.96 = 6.32
1
Figures above are offered to illustrate the ISO cycle calculation method only. They are not necessarily
representative of any particular engine/s.
106
3508 Jacket Water System Performance DM1297-00
m of ft of
H2O H2O
15
45
12
External Restriction
9 30
15
A B
C
0 0
100 170 240 310 380 450 g/min
500 800 1100 1400 1700 L/min

External Water Flow
Curve Data Curve Data
Curve Label A B C Curve Label A B C
Engine Speed rpm 1800 1600 1500 Engine Speed rpm 1800 1600 1500
Pump Speed rpm 2400 2133 2000 Pump Speed rpm 2400 2133 2000
External Flow --------------------------External Resistance --------------------- External Flow --------------------------External Resistance ---------------------
L/min --------------------------Meter of Water ----------------------------- gal/min --------------------------Feet of Water-------------------------------
159 35.8 602 10.9
169 33.8 640 10.3
180 31.5 680 9.6
185 37.1 700 11.3
190 35.8 29.2 720 10.9 8.9
201 33.5 26.9 760 10.2 8.2
211 31.2 24.6 800 9.5 7.5
222 28.9 22.0 840 8.8 6.7
232 26.2 20.0 880 8.0 6.1
238 39.4 901 12.0
243 38.4 920 11.7 7.3 5.4
254 35.8 960 10.9 6.6 4.7
243 24.0 17.7 1000 10.1 5.9 4.1
254 21.7 15.4 1040 9.2 5.1 3.4
264 33.1 19.4 13.5 1080 8.4 4.4 2.7
275 30.2 16.7 11.2 1102 2.4
285 27.6 14.4 8.9 1120 7.6 3.7
291 7.9 1160 6.8 3.0
296 24.9 12.1 1200 6.0 2.2
306 22.3 9.8 1240 5.1
317 19.7 7.2 1280 4.3
328 16.7 1320 3.5
338 14.1 1360 2.7
349 11.5 1400 1.8
359 8.9 1401 1.8
370 5.9
Engine equipped with water cooled exhaust Drive Ratio 1.33 to 1 Curves indicate maximum allowable external
manifolds or with dry exhaust manifolds. resistance.
Engine mounted expansion tank. For low speed (1300 rpm and below) ratings
Do not project curves.
2W-9726 JW Pump
107
3508B Auxiliary Pump Performance TM4143-03
m of ft of
H2O H2O
15
12 40
External Restriction 30
9
6 20
10 B
3
E
A C
D
0 0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow
Curve Label A B C D E Curve Label A B C D E
Engine Speed rpm 900 1000 1100 1200 1300 Engine Speed rpm 900 1000 1100 1200 1300
Pump Speed rpm 1800 2000 2200 2400 2600 Pump Speed rpm 1800 2000 2200 2400 2600
440 8.0 116 26.2
450 7.1 119 23.3
460 6.1 122 20.0
470 5.0 124 16.4
480 4.0 127 13.1
490 3.1 9.7 129 10.2 31.8
500 2.2 8.9 132 7.2 29.2
510 7.7 135 25.3
520 6.4 137 21.0
530 5.3 140 17.4
540 4.2 10.2 143 13.8 33.5
544 9.5 144 31.2
548 8.7 145 10.8 28.5
550 3.3 146 26.6
552 8.1 147 24.6
556 7.5 148 22.6
560 6.9 149 20.7
564 6.3 150 18.7
568 5.7 151 16.7
572 5.1 152 14.4
576 4.4 153 12.5
580 3.8 154 10.2
584 3.1 155 7.9
588 2.4 156 6.6 37.7
590 2.0 11.5 159 32.8
600 10.0 161 27.9
610 8.5 164 22.6
620 6.9 166 17.1 46.6
630 5.2 14.2 169 11.5 42.7
640 3.5 13.0 172 5.6 38.1
650 1.7 11.6 174 32.8
660 10.0 177 27.2
670 8.3 180 21.3
680 6.5 182 15.4
690 4.7 185 9.5
700 2.9
Self priming pump with 29 mm diameter pump For low speed (1300 rpm and below) ratings Curves indicate maximum allowable external
orifice plate resistance.
Pump Group 5N-5874, 4W-6674 Do not project curves.
108
3508B Auxiliary Pump Performance TM4141-03
m of ft of
H2O H2O
15
12 40
9 30
6 20
3 10
B
A C
D
0 0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow

Curve Label A B C D Curve Label A B C D
Engine Speed rpm 1200 1500 1600 1800 Engine Speed rpm 1200 1500 1600 1800
Pump Speed rpm 1600 2000 2133 2400 Pump Speed rpm 1600 2000 2133 2400
375 7.0 99 22.6
384 6.3 102 19.4
392 5.6 106 15.7
400 4.8 110 10.2
408 4.0 112 6.9
416 3.1 132 29.2
425 2.1 136 22.3
500 8.9 138 35.4
508 7.8 139 17.7
516 6.8 140 33.5
524 5.8 10.8 143 13.8 30.2
532 5.0 145 10.8 26.2
540 4.2 9.2 148 22.0
550 3.3 8.0 151 17.4
560 6.7 153 13.1
570 5.3 154 40.4
580 4.0 156 9.5 37.7
584 12.3 159 6.6 32.8
590 2.9 11.5 161 27.2
600 2.0 10.0 164 22.0
610 8.3 166 16.4
620 6.7 169 10.8
630 5.0 172 5.6
640 3.3
650 1.7
Self priming pump with 29 mm diameter pump For high speed (1301 - 1800 rpm) ratings Curves indicate maximum allowable external
109
3508 Engine Component Performance Inquiry DM1284-00
m of ft of
H2O H2O
9 30
6 20
3 10
C
A B
0 0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow

L/min --------------------------Metre of Water ----------------------------- gal/min --------------------------Feet of Water-------------------------------
454 5.7 120 18.7
460 5.4 122 17.7
477 6.9 126 22.6
480 4.6 6.8 127 15.1 22.3
500 3.9 5.9 132 12.8 19.4
520 3.2 5.1 137 10.5 16.7
522 9.3 138 30.5
540 2.5 4.3 8.4 143 8.2 14.1 27.6
560 1.8 3.7 7.5 148 5.9 12.1 24.6
579 .8 153 2.6 9.5 22.0
580 2.9 6.7 159 6.2 19.4
600 1.9 5.9 164 3.0 16.4
620 .9 5.0 169 13.5
621 .9 174 10.2
640 4.1 180 6.9
660 3.1 185 3.9
680 2.1
700 1.2
For low speed (1300 rpm and below) ratings
2W-9729 JW Pump Do not project curves.
110
3508B, 3512B, 3516B Auxiliary Pump Performance DM1277-01
m of ft of
H2O H2O
45 150
30 100
15 50
A B
0 0
200 220 240 260 280 300 g/min
800 900 1000 1100 L/min

External Water Flow

Curve Label A B Curve Label A B
Engine Speed rpm 1800 1925 Engine Speed rpm 1800 1925
Pump Speed rpm 1471 1573 Pump Speed rpm 1471 1573
770 50.0 203 164.1
780 48.2 206 158.1
800 44.6 211 146.3
820 41.1 217 134.8
840 37.5 222 123.0
856 50.0 226 164.1
860 33.9 49.2 227 111.2 161.4
880 30.4 45.2 232 99.7 148.3
900 26.8 41.2 238 87.9 135.2
920 23.2 37.2 243 76.1 122.1
940 19.6 33.2 248 64.3 108.9
960 16.1 29.2 254 52.8 95.8
980 12.6 25.2 259 41.3 82.7
995 10.0 263 32.8
1000 21.2 264 69.6
1020 17.2 269 56.4
1040 13.2 275 43.3
1056 10.0 279 32.8
111
Heat Exchanger Data Groups 3N-8888,3N-8889,4W-4632,107-1729 DM2593-00
12 70
60°
60 140°
10
Heat Transfer Capacity, Btu/min x 103

49°
Heat Transfer Capacity, kW x 102
120°
50
8 38°
100°
27° 40 81°
6
16° 61°
30
5° 41°
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250
Cooling Water Flow, L/min Cooling Water Flow, gal/min
Water Temp °C 60 49 38 27 16 5 Water Temp °F 140 120 100 81 61 41
Cooling Water Flow Heat Transfer Capacity Cooling Water Flow Heat Transfer Capacity
L/min kW kW kW kW kW kW gal/min Btu/min Btu/min Btu/min Btu/min Btu/min Btu/min

208 243 313 382 448 518 587 55 13819 17800 21724 25478 29459 33383
300 284 365 446 523 604 685 79 16151 20758 25364 29743 34349 38956
400 321 412 504 591 682 774 106 18255 23430 28662 33610 38785 44017
500 354 455 556 652 753 854 132 20132 25876 31620 37079 42823 48567
600 379 488 596 699 808 916 159 21554 27753 33894 39752 45951 52093
700 405 521 637 747 863 978 185 23032 29629 36226 42482 49079 55619
800 424 545 666 781 902 1023 211 24113 30994 37875 44415 51297 58178
833 431 554 677 794 917 1041 220 24511 31506 38501 45155 52150 59202
Performance Parameters Performance Parameters
JW Flow Through Shell: 1514 L/min JW Flow Through Shell: 400 gpm
JW Press. Drop: 68 kPa JW Press. Drop: 10 psi
JW Temp to Cooler: 99° C JW Temp to Cooler: 210° F
Curve Limits m/sec Curve Limits ft/sec

kPa psi
Min Flow – Tube Velocity — Min Flow – Tube Velocity —

Min Flow – Pressure Drop 3.3 Min Flow – Pressure Drop 0.5
Max Flow SW– Tube Velocity — Max Flow SW– Tube Velocity —
Max Flow SW– Pressure Drop 28.8 Max Flow SW– Pressure Drop 4.2
Max Flow FW – Tube Velocity — Max Flow FW – Tube Velocity —

Max Flow FW – Pressure Drop — Max Flow FW – Pressure Drop —
112
Heat Exchanger Data Groups 3N-8888, 3N-8889, 4W-4632, 107-1729 TM3968-05
12 60
140°
120°
10 60°
50

49° 100°
8 38° 40 81°
27°
61°
6 16° 30
41°
5°
4 20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 271 334 408 464 533 579 55 15412 18995 23203 26388 30312 32928
300 320 405 489 569 646 710 79 18198 23032 27809 32359 36738 40378
400 361 462 556 648 732 808 106 20530 26274 31620 36852 41629 45951
500 392 501 603 698 788 869 132 22293 28492 34293 39695 44813 49420
600 413 530 639 738 834 919 159 23487 30141 36340 41970 47429 52263
700 429 553 667 773 871 960 185 24397 31449 37932 43960 49534 54595
800 443 572 690 800 900 995 211 25193 32530 39240 45496 51183 56586
833 448 577 696 807 909 1006 220 25478 32814 39581 45894 51695 57211

kPa psi


Max Flow FW – Pressure Drop 28.8 Max Flow FW – Pressure Drop 4.2
113
Heat Exchanger Data Groups 3N-8888, 3N-8889, 4W-4632, 107-1729 DM1290-00
10 60
9 60°
140°
49° 50

8 120°
38°
7
40 100°
30°
6 86°
16°
61°
5 30
5°
41°
4
20
3
2
10
1
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 250 305 360 400 467 512 55 14217 17345 20473 22748 26558 29117
300 303 371 438 486 567 622 79 17232 21099 24909 27639 32245 35373
400 344 419 494 549 641 703 106 19563 23828 28094 31222 36454 39980
500 378 461 545 605 707 774 132 21497 26217 30994 34406 40207 44017
600 403 491 580 644 752 825 159 22919 27923 32985 36624 42766 46918
700 425 519 612 680 794 870 185 24170 29515 34804 38672 45155 49477
800 438 538 633 704 823 902 211 24909 30596 35999 40036 46804 51297
833 444 541 639 710 829 909 220 25250 30767 36340 40378 47145 51695

kPa psi


114
6 35
60°
140°
30
5
49°

120°
25
4
38° 100°
20
3
30° 86°
15
2
16° 10 61°
1
5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 30 89 148 190 257 300 55 1706 5061 8417 10805 14616 17061
300 38 110 183 235 319 372 79 2161 6256 10407 13364 18141 21156
400 43 126 211 270 366 427 106 2445 7166 12000 15355 20814 24283
500 47 138 230 295 400 466 132 2673 7848 13080 16777 22748 26501
600 51 150 245 315 426 496 159 2900 8530 13933 17914 24227 28207
700 53 154 257 330 447 521 185 3014 8758 14616 18767 25421 29629
800 55 161 269 345 467 545 211 3128 9156 15298 19620 26558 30994
833 56 164 273 350 474 553 220 3185 9327 15525 19904 26956 31449

kPa psi


115
4 20
100°
18
38°

16
3
14
86°
12
30°
2 10
6 61°
1 16°
4
5° 2 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 19 62 139 201 55 – – 1081 3526 7905 11431
300 – – 22 72 162 233 79 – – 1251 4095 9213 13251
400 – – 24 80 180 260 106 – – 1365 4550 10237 14786
500 – – 26 87 195 282 132 – – 1479 4948 11090 16037
600 – – 28 93 209 301 159 – – 1592 5289 11886 17118
700 – – 29 97 218 314 185 – – 1649 5516 12398 17857
800 – – 30 100 226 326 211 – – 1706 5687 12853 18540
833 – – 30 101 228 330 220 – – 1706 5744 12966 18767

kPa psi


116
14 80
60° 140°
70
12
49° 120°

60
10 38° 100°
50
27° 81°
8
16° 40 61°
6
5° 30 41°
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 287 369 452 530 612 694 55 16322 20985 25705 30141 34804 39468
300 346 445 544 638 737 836 79 19677 25307 30937 36283 41913 47543
400 398 512 625 733 847 961 106 22634 29117 35544 41686 48169 54652
500 435 559 683 801 925 1050 132 24738 31790 38842 45553 52605 59713
600 472 606 741 869 1004 1138 159 26843 34463 42141 49420 57097 64718
700 501 644 787 923 1066 1210 185 28492 36624 44757 52491 60623 68813
800 523 673 822 964 1113 1263 211 29743 38273 46747 54823 63296 71827
833 531 682 834 978 1129 1281 220 30198 38785 47429 55619 64206 72850

kPa psi


117
14 80
60° 140°
70
12
50° 122°

60
10 38° 100°
27° 50 81°
8
16° 61°
40
6 39°
4°
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 325 401 484 552 644 717 55 18483 22805 27525 31392 36624 40776
300 386 486 593 683 786 851 79 21952 27639 33724 38842 44700 48396
400 438 557 677 785 895 961 106 24909 31677 38501 44643 50899 54652
500 477 607 731 851 965 1041 132 27127 34520 41572 48396 54879 59202
600 506 647 775 903 1023 1113 159 28776 36795 44074 51354 58178 63296
700 533 681 810 945 1073 1175 185 30312 38728 46065 53742 61021 66822
800 556 708 839 984 1116 1229 211 31620 40264 47714 55960 63467 69893
833 563 716 848 997 1129 1245 220 32018 40719 48226 56699 64206 70803

kPa psi

Min Flow – Pressure Drop 2.1 Min Flow – Pressure Drop .3

118
12 70
60°
140°
60
10 49°
120°

38° 50
100°
8
30° 86°
40
16° 61°
6
5° 30 41°
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 297 362 428 475 555 608 55 16890 20587 24340 27013 31563 34577
300 358 433 513 571 664 731 79 20359 24625 29174 32473 37762 41572
400 403 488 576 641 737 822 106 22919 27753 32757 36454 41913 46747
500 441 534 630 700 816 896 132 25080 30369 35828 39809 46406 50955
600 469 568 672 746 869 956 159 26672 32302 38217 42425 49420 54368
700 496 600 710 790 920 1009 185 28207 34122 40378 44927 52320 57382
800 516 629 743 825 964 1057 211 29345 35771 42254 46918 54823 60111
833 522 638 752 839 978 1074 220 29686 36283 42766 47714 55619 61078

kPa psi


119
Heat Exchanger Data Groups 3N-8890, 3N8891, 4W-4642, 107-1728 DM1293-00
7 40
60° 140°
35
6
49° 120°

30
5
25
38° 100°
4
20
30° 86°
3
15
2 16° 61°
10
1 5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 35 103 172 220 298 348 55 1990 5858 9782 12511 16947 19791
300 45 131 218 280 380 443 79 2559 7450 12398 15924 21611 25193
400 50 152 251 322 434 507 106 2843 8644 14274 18312 24682 28833
500 55 168 275 353 473 552 132 3128 9554 15639 20075 26899 31392
600 61 178 292 376 502 587 159 3469 10123 16606 21383 28549 33383
700 63 184 307 393 528 616 185 3583 10464 17459 22350 30027 35032
800 65 190 316 405 549 640 211 3697 10805 17971 23032 31222 36397
833 66 192 320 410 555 648 220 3753 10919 18198 23317 31563 36852

kPa psi


120
Heat Exchanger Data Groups 3N-8890, 3N-8891, 4W4642, 107-1728 DM2576-00
5 25
100°

4 38° 20
86°
3 15
30°
2 10
61°
16°
1 5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 22 73 165 239 55 – – 1251 4152 9384 13592
300 – – 26 86 194 280 79 – – 1479 4891 11033 15924
400 – – 29 97 218 314 106 – – 1649 5516 12398 17857
500 – – 31 105 235 340 132 – – 1763 5971 13364 19336
600 – – 33 111 250 362 159 – – 1877 6313 14217 20587
700 – – 35 116 262 378 185 – – 1990 6597 14900 21497
800 – – 36 120 271 391 211 – – 2047 6824 15412 22236
833 – – 37 122 274 395 220 – – 2104 6938 15582 22464

kPa psi


121
Heat Exchanger Data Groups 3N-8892, 3N-8893, 4W4652, 107-1730 TM3833-06
18 100
136°
16 60° 90

80 122°
14 50°
70 100°
12 38°
60 81°
27°
10
16° 50 61°
8
4° 40 39°
6
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 360 459 550 668 754 853 55 20473 26103 31278 37989 42880 48510
300 449 580 697 812 911 1018 79 25535 32985 39638 46178 51808 57894
400 524 671 809 927 1038 1164 106 29800 38160 46008 52718 59031 66197
500 577 730 881 1009 1129 1280 132 32814 41515 50102 57382 64206 72793
600 615 777 940 1078 1208 1383 159 34975 44188 53458 61306 68699 78651
700 650 817 991 1139 1280 1479 185 36965 46463 56358 64775 72793 84111
800 678 852 1037 1196 1347 1569 211 38558 48453 58974 68016 76604 89229
833 686 863 1050 1213 1368 1597 220 39013 49079 59713 68983 77798 90821

kPa psi


122
14 80
60° 140°
70
12

49° 120°
60
10
38° 100°
50
8
27° 81°
40
6 16° 61°
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 315 405 495 580 670 – 55 17914 23032 28151 32985 38103 –
300 381 490 599 703 812 – 79 21667 27866 34065 39980 46178 –
400 439 565 690 810 935 – 106 24966 32131 39240 46065 53173 –
500 484 622 760 891 1029 – 132 27525 35373 43221 50671 58519 –
600 522 671 821 962 1112 – 159 29686 38160 46690 54709 63239 –
700 553 710 868 1018 1176 – 185 31449 40378 49363 57894 66879 –
800 575 739 903 1059 1223 – 211 32700 42027 51354 60225 69552 –
833 586 753 920 1079 1247 – 220 33326 42823 52320 61363 70917 –

kPa psi


123
14 80
60° 140°
12 70
49° 120°

60
10
38° 100°
30° 50 86°
8
16° 61°
40
6 5° 41°
30
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 338 412 486 540 631 691 55 19222 23430 27639 30710 35885 39297
300 401 489 577 641 749 820 79 22805 27809 32814 36454 42596 46633
400 459 559 659 729 855 939 106 26103 31790 37477 41458 48624 53401
500 500 612 720 800 934 1024 132 28435 34804 40946 45496 53116 58235
600 537 654 771 856 1000 1097 159 30539 37193 43847 48681 56870 62386
700 567 692 815 906 1058 1160 185 32245 39354 46349 51524 60168 65969
800 594 724 855 950 1110 1217 211 33781 41174 48624 54026 63126 69211
833 600 731 867 964 1125 1235 220 34122 41572 49306 54823 63979 70234

kPa psi


124
8 45
60° 140°
7 40

49° 120°
35
30
5
38° 100°
25
4 27° 81°
20
3
15
16° 61°
2
10
1 5° 5 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 50 129 212 267 352 400 55 2843 7336 12056 15184 20018 22748
300 60 153 252 315 419 477 79 3412 8701 14331 17914 23828 27127
400 67 170 280 360 474 542 106 3810 9668 15924 20473 26956 30823
500 75 192 316 395 520 596 132 4265 10919 17971 22464 29572 33894
600 81 207 340 424 558 636 159 4606 11772 19336 24113 31733 36169
700 85 217 356 450 590 673 185 4834 12341 20246 25591 33553 38273
800 89 229 376 470 622 708 211 5061 13023 21383 26729 35373 40264
833 90 231 380 475 630 717 220 5118 13137 21611 27013 35828 40776

kPa psi


125
5 30
38°
100°
25

4
20
30°
3 86°
15
2
10
16° 61°
1
5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 24 81 181 262 55 – – 1365 4606 10293 14900
300 – – 29 96 215 310 79 – – 1649 5460 12227 17630
400 – – 32 108 242 350 106 – – 1820 6142 13763 19904
500 – – 35 117 264 381 132 – – 1990 6654 15014 21667
600 – – 37 124 280 404 159 – – 2104 7052 15924 22975
700 – – 39 130 293 423 185 – – 2218 7393 16663 24056
800 – – 41 135 304 439 211 – – 2332 7677 17288 24966
833 – – 41 137 307 444 220 – – 2332 7791 17459 25250

kPa psi


126
3512B Jacket Water System Performance DM1298-00
m of ft of
H2O H2O
15
45
12
9 30
15
C
3 A B
0 0
250 300 350 400 450 500 g/min
1000 1200 1400 1600 1800 L/min

External Water Flow

1102 7.3 291 24.0
1120 7.1 296 23.3
1158 8.5 306 27.9 22.0
1160 8.5 6.7 317 26.6 20.7
1200 8.1 6.3 328 25.3 19.4
1240 7.7 5.9 338 24.0 18.4
1280 7.3 5.6 343 36.1 17.1
1298 11.0 349 22.6 15.7
1300 11.0 359 21.3
1320 6.9 5.2 370 32.2 19.7 14.4
1360 6.5 4.8 380 18.4 13.1
1400 9.8 6.0 4.4 391 17.1 11.8
1440 5.6 4.0 396 28.2 11.2
1480 5.2 3.6 402 15.7
1499 3.4 412 14.1
1500 8.6 423 24.0 12.8
1520 4.8 431 11.8
1560 4.3 449 20.3
1600 7.3 3.9 476 16.7
1632 3.6 502 12.8
1700 6.2
1800 5.1
1900 3.9
Engine equipped with water cooled exhaust Drive Ratio 1.33 to 1

manifolds or with dry exhaust manifolds.
Engine mounted expansion tank.
2W-9729 JW Pump
127
3512B Low Speed Auxiliary Pump Performance TM4143-03
m of ft of
H2O H2O
15
12 40
9
6 20
10 B
3
E
A C
D
0 0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow
440 8.0 116 26.2
450 7.1 119 23.3
460 6.1 122 20.0
470 5.0 124 16.4
480 4.0 127 13.1
490 3.1 9.7 129 10.2 31.8
500 2.2 8.9 132 7.2 29.2
510 7.7 135 25.3
520 6.4 137 21.0
530 5.3 140 17.4
540 4.2 10.2 143 13.8 33.5
544 9.5 144 31.2
548 8.7 145 10.8 28.5
550 3.3 146 26.6
552 8.1 147 24.6
556 7.5 148 22.6
560 6.9 149 20.7
564 6.3 150 18.7
568 5.7 151 16.7
572 5.1 152 14.4
576 4.4 153 12.5
580 3.8 154 10.2
584 3.1 155 7.9
588 2.4 156 6.6 37.7
590 2.0 11.5 159 32.8
600 10.0 161 27.9
610 8.5 164 22.6
620 6.9 166 17.1 46.6
630 5.2 14.2 169 11.5 42.7
640 3.5 13.0 172 5.6 38.1
650 1.7 11.6 174 32.8
660 10.0 177 27.2
670 8.3 180 21.3
680 6.5 182 15.4
690 4.7 185 9.5
700 2.9

Pump Group 5N-5874, 4W-6674
128
3512 High Speed Auxiliary Pump Performance TM4141-03
m of ft of
H2O H2O
15
12 40
9 30
6 20
3 10
B
A C
D
0 0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow

375 7.0 99 22.6
384 6.3 102 19.4
392 5.6 106 15.7
400 4.8 110 10.2
408 4.0 112 6.9
416 3.1 132 29.2
425 2.1 136 22.3
500 8.9 138 35.4
508 7.8 139 17.7
516 6.8 140 33.5
524 5.8 10.8 143 13.8 30.2
532 5.0 145 10.8 26.2
540 4.2 9.2 148 22.0
550 3.3 8.0 151 17.4
560 6.7 153 13.1
570 5.3 154 40.4
580 4.0 156 9.5 37.7
584 12.3 159 6.6 32.8
590 2.9 11.5 161 27.2
600 2.0 10.0 164 22.0
610 8.3 166 16.4
620 6.7 169 10.8
630 5.0 172 5.6
640 3.3
650 1.7

Pump Group 5N-5874, 4W-6674
129
3512B SCAC Pump – Pump Gp 9Y5710 & 7E9782 DM1285-00
m of ft of
H2O H2O
15
45
12
9 30
15
B
A C
0 0
100 170 240 310 380 450 g/min
500 800 1100 1400 1700 L/min

External Water Flow

439 5.7 116 18.7
440 5.7 122 16.4 22.6
460 5.0 126 30.5
462 6.9 127 13.5 20.3 29.5
477 9.3 132 11.5 17.4 28.9
480 4.1 6.2 9.0 137 8.5 15.1 29.2
500 3.5 5.3 8.8 143 6.2 12.5 25.9
520 2.6 4.6 8.9 148 3.6 9.5 22.6
540 1.9 3.8 7.9 153 6.6 20.0
560 1.1 2.9 6.9 159 4.3 17.1
580 2.0 6.1 164 13.8
600 1.3 5.2 169 10.5
620 1.2 4.2 174 7.2
640 3.2 180 3.9
660 2.2
680 1.2
681 1.2
2W-9729 JW Pump
130
3508B,3516B,3512B Auxiliary Pump Performance DM1277-01
m of ft of
H2O H2O
45 150
30 100
15 50
A B
0 0
200 220 240 260 280 300 g/min
800 900 1000 1100 L/min

External Water Flow

770 50.0 203 164.1
780 48.2 206 158.1
800 44.6 211 146.3
820 41.1 217 134.8
840 37.5 222 123.0
856 50.0 226 164.1
860 33.9 49.2 227 111.2 161.4
880 30.4 45.2 232 99.7 148.3
900 26.8 41.2 238 87.9 135.2
920 23.2 37.2 243 76.1 122.1
940 19.6 33.2 248 64.3 108.9
960 16.1 29.2 254 52.8 95.8
980 12.6 25.2 259 41.3 82.7
995 10.0 263 32.8
1000 21.2 264 69.6
1020 17.2 269 56.4
1040 13.2 275 43.3
1056 10.0 279 32.8
131
Heat Exchanger Data Groups 3N-8888,3N-8889,4W-4632,107-1729 DM2593-00
12 70
5°
60 41°
10

16°
61°
50
8 27°
81°
38° 40 100°
6
49° 120°
30
60° 140°
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 243 313 382 448 518 587 55 13819 17800 21724 25478 29459 33383
300 284 365 446 523 604 685 79 16151 20758 25364 29743 34349 38956
400 321 412 504 591 682 774 106 18255 23430 28662 33610 38785 44017
500 354 455 556 652 753 854 132 20132 25876 31620 37079 42823 48567
600 379 488 596 699 808 916 159 21554 27753 33894 39752 45951 52093
700 405 521 637 747 863 978 185 23032 29629 36226 42482 49079 55619
800 424 545 666 781 902 1023 211 24113 30994 37875 44415 51297 58178
833 431 554 677 794 917 1041 220 24511 31506 38501 45155 52150 59202

JW Temp to Cooler: 99 °C JW Temp to Cooler: 210° F

kPa psi

Max Flow SW – Tube Velocity — Max Flow SW – Tube Velocity —

Max Flow SW – Pressure Drop 28.8 Max Flow SW – Pressure Drop 4.2

132
12 60
41°
61°
10 5° 50

16° 81°
8 27° 100°
40
38°
120°
6 49° 30
140°
60°
4 20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 271 334 408 464 533 579 55 15412 18995 23203 26388 30312 32928
300 320 405 489 569 646 710 79 18198 23032 27809 32359 36738 40378
400 361 462 556 648 732 808 106 20530 26274 31620 36852 41629 45951
500 392 501 603 698 788 869 132 22293 28492 34293 39695 44813 49420
600 413 530 639 738 834 919 159 23487 30141 36340 41970 47429 52263
700 429 553 667 773 871 960 185 24397 31449 37932 43960 49534 54595
800 443 572 690 800 900 995 211 25193 32530 39240 45496 51183 56586
833 448 577 696 807 909 1006 220 25478 32814 39581 45894 51695 57211
JW Temp to Cooler: 99 °C JW Temp to Cooler: 210 °F

kPa psi



133
10 60
5°
9
41°
16° 50

8 61°
30°
7
40 86°
38°
6 100°
49°
120°
5 30
60°
140°
4
20
3
2
10
1
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 250 305 360 400 467 512 55 14217 17345 20473 22748 26558 29117
300 303 371 438 486 567 622 79 17232 21099 24909 27639 32245 35373
400 344 419 494 549 641 703 106 19563 23828 28094 31222 36454 39980
500 378 461 545 605 707 774 132 21497 26217 30994 34406 40207 44017
600 403 491 580 644 752 825 159 22919 27923 32985 36624 42766 46918
700 425 519 612 680 794 870 185 24170 29515 34804 38672 45155 49477
800 438 538 633 704 823 902 211 24909 30596 35999 40036 46804 51297
833 444 541 639 710 829 909 220 25250 30767 36340 40378 47145 51695

kPa psi



134
6 35
5°
41°
30
5

16°
61°
25
4
30° 86°
20
3
38°
100°
15
2
49° 10 120°
1
5
60° 140°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250


208 30 89 148 190 257 300 55 1706 5061 8417 10805 14616 17061
300 38 110 183 235 319 372 79 2161 6256 10407 13364 18141 21156
400 43 126 211 270 366 427 106 2445 7166 12000 15355 20814 24283
500 47 138 230 295 400 466 132 2673 7848 13080 16777 22748 26501
600 51 150 245 315 426 496 159 2900 8530 13933 17914 24227 28207
700 53 154 257 330 447 521 185 3014 8758 14616 18767 25421 29629
800 55 161 269 345 467 545 211 3128 9156 15298 19620 26558 30994
833 56 164 273 350 474 553 220 3185 9327 15525 19904 26956 31449

kPa psi

Max Flow SW – Tube Velocity ------- Max Flow SW – Tube Velocity -------
— —
Max Flow SW – Pressure Drop ------- Max Flow SW – Pressure Drop -------
17.2 2.5
Max Flow FW– Tube Velocity — Max Flow FW– Tube Velocity —
Max Flow FW– Pressure Drop 28.8 Max Flow FW– Pressure Drop 4.2
135
4 20
41°
18
5°

16
3
14
61°
12
16°
2 10
6 86°
1 30°
4
2 100°
38°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 19 62 139 201 55 – – 1081 3526 7905 11431
300 – – 22 72 162 233 79 – – 1251 4095 9213 13251
400 – – 24 80 180 260 106 – – 1365 4550 10237 14786
500 – – 26 87 195 282 132 – – 1479 4948 11090 16037
600 – – 28 93 209 301 159 – – 1592 5289 11886 17118
700 – – 29 97 218 314 185 – – 1649 5516 12398 17857
800 – – 30 100 226 326 211 – – 1706 5687 12853 18540
833 – – 30 101 228 330 220 – – 1706 5744 12966 18767

kPa psi



136
14 80
5° 41°
12 70
16° 61°

60
10 27° 81°
38° 50
100°
8
49° 40 120°
6
60° 140°
30
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250


208 287 369 452 530 612 694 55 16322 20985 25705 30141 34804 39468
300 346 445 544 638 737 836 79 19677 25307 30937 36283 41913 47543
400 398 512 625 733 847 961 106 22634 29117 35544 41686 48169 54652
500 435 559 683 801 925 1050 132 24738 31790 38842 45553 52605 59713
600 472 606 741 869 1004 1138 159 26843 34463 42141 49420 57097 64718
700 501 644 787 923 1066 1210 185 28492 36624 44757 52491 60623 68813
800 523 673 822 964 1113 1263 211 29743 38273 46747 54823 63296 71827
833 531 682 834 978 1129 1281 220 30198 38785 47429 55619 64206 72850

kPa psi

— —
2.3 2.3
137
14 80
4° 39°
70
12
16° 61°

60
10 27° 81°
38° 50 100°
8
50° 122°
40
6
60° 140°
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 325 401 484 552 644 717 55 18483 22805 27525 31392 36624 40776
300 386 486 593 683 786 851 79 21952 27639 33724 38842 44700 48396
400 438 557 677 785 895 961 106 24909 31677 38501 44643 50899 54652
500 477 607 731 851 965 1041 132 27127 34520 41572 48396 54879 59202
600 506 647 775 903 1023 1113 159 28776 36795 44074 51354 58178 63296
700 533 681 810 945 1073 1175 185 30312 38728 46065 53742 61021 66822
800 556 708 839 984 1116 1229 211 31620 40264 47714 55960 63467 69893
833 563 716 848 997 1129 1245 220 32018 40719 48226 56699 64206 70803

kPa psi



138
12 70
5°
41°
60
10 16°
61°

30° 50
86°
8
38° 100°
40
49° 120°
6
60° 30 140°
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250


208 297 362 428 475 555 608 55 16890 20587 24340 27013 31563 34577
300 358 433 513 571 664 731 79 20359 24625 29174 32473 37762 41572
400 403 488 576 641 737 822 106 22919 27753 32757 36454 41913 46747
500 441 534 630 700 816 896 132 25080 30369 35828 39809 46406 50955
600 469 568 672 746 869 956 159 26672 32302 38217 42425 49420 54368
700 496 600 710 790 920 1009 185 28207 34122 40378 44927 52320 57382
800 516 629 743 825 964 1057 211 29345 35771 42254 46918 54823 60111
833 522 638 752 839 978 1074 220 29686 36283 42766 47714 55619 61078

kPa psi

— —
15.9 2.3
139
7 40
5° 41°
35
6

16° 61°
30
5
25
30° 86°
4
20
38° 100°
3
15
2 49° 120°
10
1 5
60° 140°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 35 103 172 220 298 348 55 1990 5858 9782 12511 16947 19791
300 45 131 218 280 380 443 79 2559 7450 12398 15924 21611 25193
400 50 152 251 322 434 507 106 2843 8644 14274 18312 24682 28833
500 55 168 275 353 473 552 132 3128 9554 15639 20075 26899 31392
600 61 178 292 376 502 587 159 3469 10123 16606 21383 28549 33383
700 63 184 307 393 528 616 185 3583 10464 17459 22350 30027 35032
800 65 190 316 405 549 640 211 3697 10805 17971 23032 31222 36397
833 66 192 320 410 555 648 220 3753 10919 18198 23317 31563 36852

kPa psi



140
5 25
41°
5°

4 20
61°
3 15
16°
2 10
86°
30°
1 5
38° 100°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250


208 – – 22 73 165 239 55 – – 1251 4152 9384 13592
300 – – 26 86 194 280 79 – – 1479 4891 11033 15924
400 – – 29 97 218 314 106 – – 1649 5516 12398 17857
500 – – 31 105 235 340 132 – – 1763 5971 13364 19336
600 – – 33 111 250 362 159 – – 1877 6313 14217 20587
700 – – 35 116 262 378 185 – – 1990 6597 14900 21497
800 – – 36 120 271 391 211 – – 2047 6824 15412 22236
833 – – 37 122 274 395 220 – – 2104 6938 15582 22464

kPa psi

— —
16.0 2.3
Max Flow FW– Pressure Drop — Max Flow FW– Pressure Drop —
141
18 100
39°
16 4° 90

80 61°
14 16°
70 81°
12 27°
38° 60 100°
10
50° 50 122°
8
60° 40 136°
6
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 360 459 550 668 754 853 55 20473 26103 31278 37989 42880 48510
300 449 580 697 812 911 1018 79 25535 32985 39638 46178 51808 57894
400 524 671 809 927 1038 1164 106 29800 38160 46008 52718 59031 66197
500 577 730 881 1009 1129 1280 132 32814 41515 50102 57382 64206 72793
600 615 777 940 1078 1208 1383 159 34975 44188 53458 61306 68699 78651
700 650 817 991 1139 1280 1479 185 36965 46463 56358 64775 72793 84111
800 678 852 1037 1196 1347 1569 211 38558 48453 58974 68016 76604 89229
833 686 863 1050 1213 1368 1597 220 39013 49079 59713 68983 77798 90821

kPa psi



142
14 80
16° 61°
70
12

27° 81°
60
10
38° 100°
50
8
49° 120°
40
6 60° 140°
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250


208 315 405 495 580 670 – 55 17914 23032 28151 32985 38103 –
300 381 490 599 703 812 – 79 21667 27866 34065 39980 46178 –
400 439 565 690 810 935 – 106 24966 32131 39240 46065 53173 –
500 484 622 760 891 1029 – 132 27525 35373 43221 50671 58519 –
600 522 671 821 962 1112 – 159 29686 38160 46690 54709 63239 –
700 553 710 868 1018 1176 – 185 31449 40378 49363 57894 66879 –
800 575 739 903 1059 1223 – 211 32700 42027 51354 60225 69552 –
833 586 753 920 1079 1247 – 220 33326 42823 52320 61363 70917 –

kPa psi

— —
19.3 2.8
143
14 80
5° 41°
12 70
16° 61°

60
10
30° 86°
38° 50 100°
8
49° 120°
40
6 60° 140°
30
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 338 412 486 540 631 691 55 19222 23430 27639 30710 35885 39297
300 401 489 577 641 749 820 79 22805 27809 32814 36454 42596 46633
400 459 559 659 729 855 939 106 26103 31790 37477 41458 48624 53401
500 500 612 720 800 934 1024 132 28435 34804 40946 45496 53116 58235
600 537 654 771 856 1000 1097 159 30539 37193 43847 48681 56870 62386
700 567 692 815 906 1058 1160 185 32245 39354 46349 51524 60168 65969
800 594 724 855 950 1110 1217 211 33781 41174 48624 54026 63126 69211
833 600 731 867 964 1125 1235 220 34122 41572 49306 54823 63979 70234

kPa psi



144
8 45
5° 41°
7 40
61°

16°
35
30
5
27° 81°
25
4 38° 100°
20
3
15
49° 120°
2
10
1 60° 5 140°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250


208 50 129 212 267 352 400 55 2843 7336 12056 15184 20018 22748
300 60 153 252 315 419 477 79 3412 8701 14331 17914 23828 27127
400 67 170 280 360 474 542 106 3810 9668 15924 20473 26956 30823
500 75 192 316 395 520 596 132 4265 10919 17971 22464 29572 33894
600 81 207 340 424 558 636 159 4606 11772 19336 24113 31733 36169
700 85 217 356 450 590 673 185 4834 12341 20246 25591 33553 38273
800 89 229 376 470 622 708 211 5061 13023 21383 26729 35373 40264
833 90 231 380 475 630 717 220 5118 13137 21611 27013 35828 40776

kPa psi

— —
19.3 2.8
145
5 30
5°
41°
25

4
20
16°
3 61°
15
2
10
30° 86°
1
5
38° 100°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 24 81 181 262 55 – – 1365 4606 10293 14900
300 – – 29 96 215 310 79 – – 1649 5460 12227 17630
400 – – 32 108 242 350 106 – – 1820 6142 13763 19904
500 – – 35 117 264 381 132 – – 1990 6654 15014 21667
600 – – 37 124 280 404 159 – – 2104 7052 15924 22975
700 – – 39 130 293 423 185 – – 2218 7393 16663 24056
800 – – 41 135 304 439 211 – – 2332 7677 17288 24966
833 – – 41 137 307 444 220 – – 2332 7791 17459 25250

kPa psi



146
3516B Jacket Water System Performance DM1299-00
m of ft of
H2O H2O
15
45
12
9 30
C
6
B
A
15
0 0
250 300 350 400 450 500 g/min
1000 1200 1400 1600 1800 L/min

External Water Flow

1802 6.8 264 36.7
1800 6.8 275 35.1
1700 8.4 282 42.0
1601 5.7 285 32.8
1600 9.8 5.7 291 40.7
1500 11.4 7.0 296 30.8
1499 5.1 306 29.5
1480 5.4 317 52.8 36.4 28.2
1440 5.8 328 26.9
1400 12.9 8.4 6.3 338 24.9
1360 6.8 343 46.9 31.8
1320 7.2 349 23.6
1300 14.3 9.7 359 22.3
1280 7.6 370 42.3 27.6 20.7
1240 8.2 380 19.0
1200 16.1 11.1 8.6 391 17.7
1160 9.0 396 37.4 23.0 16.7
1120 9.4 423 32.2 18.7
1100 12.4 449 27.6
1080 10.0 476 22.3
1067 12.8
1040 10.7
1000 11.2
999 11.2
Engine equipped with water cooled exhaust Drive Ratio 1.33 to 1

manifolds or with dry exhaust manifolds.
Engine mounted expansion tank.
2W-9729 JW Pump
147
3516B Low Speed Auxiliary Pump Performance TM4143-03
m of ft of
H2O H2O
15
12 40
9
6 20
10 B
3
E
A C
D
0 0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow
440 8.0 116 26.2
450 7.1 119 23.3
460 6.1 122 20.0
470 5.0 124 16.4
480 4.0 127 13.1
490 3.1 9.7 129 10.2 31.8
500 2.2 8.9 132 7.2 29.2
510 7.7 135 25.3
520 6.4 137 21.0
530 5.3 140 17.4
540 4.2 10.2 143 13.8 33.5
544 9.5 144 31.2
548 8.7 145 10.8 28.5
550 3.3 146 26.6
552 8.1 147 24.6
556 7.5 148 22.6
560 6.9 149 20.7
564 6.3 150 18.7
568 5.7 151 16.7
572 5.1 152 14.4
576 4.4 153 12.5
580 3.8 154 10.2
584 3.1 155 7.9
588 2.4 156 6.6 37.7
590 2.0 11.5 159 32.8
600 10.0 161 27.9
610 8.5 164 22.6
620 6.9 166 17.1 46.6
630 5.2 14.2 169 11.5 42.7
640 3.5 13.0 172 5.6 38.1
650 1.7 11.6 174 32.8
660 10.0 177 27.2
670 8.3 180 21.3
680 6.5 182 15.4
690 4.7 185 9.5
700 2.9
148
3516 High Speed Auxiliary Pump Performance TM4141-03
m of ft of
H2O H2O
15
12 40
9 30
6 20
3 10
B
A C
D
0 0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow

375 7.0 99 22.6
384 6.3 102 19.4
392 5.6 106 15.7
400 4.8 110 10.2
408 4.0 112 6.9
416 3.1 132 29.2
425 2.1 136 22.3
500 8.9 138 35.4
508 7.8 139 17.7
516 6.8 140 33.5
524 5.8 10.8 143 13.8 30.2
532 5.0 145 10.8 26.2
540 4.2 9.2 148 22.0
550 3.3 8.0 151 17.4
560 6.7 153 13.1
570 5.3 154 40.4
580 4.0 156 9.5 37.7
584 12.3 159 6.6 32.8
590 2.9 11.5 161 27.2
600 2.0 10.0 164 22.0
610 8.3 166 16.4
620 6.7 169 10.8
630 5.0 172 5.6
640 3.3
650 1.7
149
3516B LOW SPEED Jacket Water System Performance DM1286-00
m of ft of
H2O H2O
15
12 40
External Restriction 9 30
6 20
3 10
C
0
A B
0
100 120 140 160 180 200 g/min
400 500 600 700 L/min

External Water Flow
413 5.7 109 18.7
420 5.4 111 17.7
435 6.9 115 22.6
440 4.5 6.6 116 14.8 21.7
460 3.6 5.5 122 11.8 18.0
477 9.3 126 30.5
480 2.7 4.6 9.1 127 8.9 15.1 29.9
500 2.0 3.8 8.1 132 6.6 12.5 26.6
520 .9 3.0 7.1 137 3.0 9.8 23.3
540 .2 2.0 6.0 143 .7 6.6 19.7
560 1.0 5.0 148 3.3 16.4
575 .3 152 1.0
580 4.0 153 13.1
600 3.0 159 9.8
620 2.0 164 6.6
640 .7 169 2.3
150
3508B,3516B,3512B Auxiliary Pump Performance DM1277-01
m of ft of
H2O H2O
45 150
30 100
15 50
A B
0 0
200 220 240 260 280 300 g/min
800 900 1000 1100 L/min

External Water Flow

770 50.0 203 164.1
780 48.2 206 158.1
800 44.6 211 146.3
820 41.1 217 134.8
840 37.5 222 123.0
856 50.0 226 164.1
860 33.9 49.2 227 111.2 161.4
880 30.4 45.2 232 99.7 148.3
900 26.8 41.2 238 87.9 135.2
920 23.2 37.2 243 76.1 122.1
940 19.6 33.2 248 64.3 108.9
960 16.1 29.2 254 52.8 95.8
980 12.6 25.2 259 41.3 82.7
995 10.0 263 32.8
1000 21.2 264 69.6
1020 17.2 269 56.4
1040 13.2 275 43.3
1056 10.0 279 32.8
151
Heat Exchanger Data Groups
Groups 3N8890, 3N8891, 4W4642
3N-8888,3N-8889,4W-4632,107-1729 TM3969-04
DM2593-00
12 70
60°
60 140°
10

49°
120°
50
8 38°
100°
27° 40 81°
6
16° 61°
30
5° 41°
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 243 313 382 448 518 587 55 13819 17800 21724 25478 29459 33383
300 284 365 446 523 604 685 79 16151 20758 25364 29743 34349 38956
400 321 412 504 591 682 774 106 18255 23430 28662 33610 38785 44017
500 354 455 556 652 753 854 132 20132 25876 31620 37079 42823 48567
600 379 488 596 699 808 916 159 21554 27753 33894 39752 45951 52093
700 405 521 637 747 863 978 185 23032 29629 36226 42482 49079 55619
800 424 545 666 781 902 1023 211 24113 30994 37875 44415 51297 58178
833 431 554 677 794 917 1041 220 24511 31506 38501 45155 52150 59202

kPa psi


152
12 60
140°
120°
10 60°
50

49° 100°
8 38° 40 81°
27°
61°
6 16° 30
41°
5°
4 20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 271 334 408 464 533 579 55 15412 18995 23203 26388 30312 32928
300 320 405 489 569 646 710 79 18198 23032 27809 32359 36738 40378
400 361 462 556 648 732 808 106 20530 26274 31620 36852 41629 45951
500 392 501 603 698 788 869 132 22293 28492 34293 39695 44813 49420
600 413 530 639 738 834 919 159 23487 30141 36340 41970 47429 52263
700 429 553 667 773 871 960 185 24397 31449 37932 43960 49534 54595
800 443 572 690 800 900 995 211 25193 32530 39240 45496 51183 56586
833 448 577 696 807 909 1006 220 25478 32814 39581 45894 51695 57211

kPa psi


153
10 60
9 60°
140°
49° 50

8 120°
38°
7
40 100°
30°
6 86°
16°
61°
5 30
5°
41°
4
20
3
2
10
1
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 250 305 360 400 467 512 55 14217 17345 20473 22748 26558 29117
300 303 371 438 486 567 622 79 17232 21099 24909 27639 32245 35373
400 344 419 494 549 641 703 106 19563 23828 28094 31222 36454 39980
500 378 461 545 605 707 774 132 21497 26217 30994 34406 40207 44017
600 403 491 580 644 752 825 159 22919 27923 32985 36624 42766 46918
700 425 519 612 680 794 870 185 24170 29515 34804 38672 45155 49477
800 438 538 633 704 823 902 211 24909 30596 35999 40036 46804 51297
833 444 541 639 710 829 909 220 25250 30767 36340 40378 47145 51695

kPa psi


154
6 35
60°
140°
30
5
49°

120°
25
4
38° 100°
20
3
30° 86°
15
2
16° 10 61°
1
5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 30 89 148 190 257 300 55 1706 5061 8417 10805 14616 17061
300 38 110 183 235 319 372 79 2161 6256 10407 13364 18141 21156
400 43 126 211 270 366 427 106 2445 7166 12000 15355 20814 24283
500 47 138 230 295 400 466 132 2673 7848 13080 16777 22748 26501
600 51 150 245 315 426 496 159 2900 8530 13933 17914 24227 28207
700 53 154 257 330 447 521 185 3014 8758 14616 18767 25421 29629
800 55 161 269 345 467 545 211 3128 9156 15298 19620 26558 30994
833 56 164 273 350 474 553 220 3185 9327 15525 19904 26956 31449

kPa psi


155
4 20
100°
18
38°

16
3
14
86°
12
30°
2 10
6 61°
1 16°
4
5° 2 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 19 62 139 201 55 – – 1081 3526 7905 11431
300 – – 22 72 162 233 79 – – 1251 4095 9213 13251
400 – – 24 80 180 260 106 – – 1365 4550 10237 14786
500 – – 26 87 195 282 132 – – 1479 4948 11090 16037
600 – – 28 93 209 301 159 – – 1592 5289 11886 17118
700 – – 29 97 218 314 185 – – 1649 5516 12398 17857
800 – – 30 100 226 326 211 – – 1706 5687 12853 18540
833 – – 30 101 228 330 220 – – 1706 5744 12966 18767

kPa psi


156
14 80
60° 140°
70
12
49° 120°

60
10 38° 100°
50
27° 81°
8
16° 40 61°
6
5° 30 41°
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 287 369 452 530 612 694 55 16322 20985 25705 30141 34804 39468
300 346 445 544 638 737 836 79 19677 25307 30937 36283 41913 47543
400 398 512 625 733 847 961 106 22634 29117 35544 41686 48169 54652
500 435 559 683 801 925 1050 132 24738 31790 38842 45553 52605 59713
600 472 606 741 869 1004 1138 159 26843 34463 42141 49420 57097 64718
700 501 644 787 923 1066 1210 185 28492 36624 44757 52491 60623 68813
800 523 673 822 964 1113 1263 211 29743 38273 46747 54823 63296 71827
833 531 682 834 978 1129 1281 220 30198 38785 47429 55619 64206 72850

kPa psi


157
14 80
60° 140°
70
12
50° 122°

60
10 38° 100°
27° 50 81°
8
16° 61°
40
6 39°
4°
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 325 401 484 552 644 717 55 18483 22805 27525 31392 36624 40776
300 386 486 593 683 786 851 79 21952 27639 33724 38842 44700 48396
400 438 557 677 785 895 961 106 24909 31677 38501 44643 50899 54652
500 477 607 731 851 965 1041 132 27127 34520 41572 48396 54879 59202
600 506 647 775 903 1023 1113 159 28776 36795 44074 51354 58178 63296
700 533 681 810 945 1073 1175 185 30312 38728 46065 53742 61021 66822
800 556 708 839 984 1116 1229 211 31620 40264 47714 55960 63467 69893
833 563 716 848 997 1129 1245 220 32018 40719 48226 56699 64206 70803

kPa psi


158
12 70
60°
140°
60
10 49°
120°

38° 50
100°
8
30° 86°
40
16° 61°
6
5° 30 41°
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 297 362 428 475 555 608 55 16890 20587 24340 27013 31563 34577
300 358 433 513 571 664 731 79 20359 24625 29174 32473 37762 41572
400 403 488 576 641 737 822 106 22919 27753 32757 36454 41913 46747
500 441 534 630 700 816 896 132 25080 30369 35828 39809 46406 50955
600 469 568 672 746 869 956 159 26672 32302 38217 42425 49420 54368
700 496 600 710 790 920 1009 185 28207 34122 40378 44927 52320 57382
800 516 629 743 825 964 1057 211 29345 35771 42254 46918 54823 60111
833 522 638 752 839 978 1074 220 29686 36283 42766 47714 55619 61078

kPa psi


159
7 40
60° 140°
35
6
49° 120°

30
5
25
38° 100°
4
20
30° 86°
3
15
2 16° 61°
10
1 5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 35 103 172 220 298 348 55 1990 5858 9782 12511 16947 19791
300 45 131 218 280 380 443 79 2559 7450 12398 15924 21611 25193
400 50 152 251 322 434 507 106 2843 8644 14274 18312 24682 28833
500 55 168 275 353 473 552 132 3128 9554 15639 20075 26899 31392
600 61 178 292 376 502 587 159 3469 10123 16606 21383 28549 33383
700 63 184 307 393 528 616 185 3583 10464 17459 22350 30027 35032
800 65 190 316 405 549 640 211 3697 10805 17971 23032 31222 36397
833 66 192 320 410 555 648 220 3753 10919 18198 23317 31563 36852

kPa psi


160
5 25
100°

4 38° 20
86°
3 15
30°
2 10
61°
16°
1 5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 22 73 165 239 55 – – 1251 4152 9384 13592
300 – – 26 86 194 280 79 – – 1479 4891 11033 15924
400 – – 29 97 218 314 106 – – 1649 5516 12398 17857
500 – – 31 105 235 340 132 – – 1763 5971 13364 19336
600 – – 33 111 250 362 159 – – 1877 6313 14217 20587
700 – – 35 116 262 378 185 – – 1990 6597 14900 21497
800 – – 36 120 271 391 211 – – 2047 6824 15412 22236
833 – – 37 122 274 395 220 – – 2104 6938 15582 22464

kPa psi


161
18 100
136°
16 60° 90

80 122°
14 50°
70 100°
12 38°
60 81°
27°
10
16° 50 61°
8
4° 40 39°
6
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 360 459 550 668 754 853 55 20473 26103 31278 37989 42880 48510
300 449 580 697 812 911 1018 79 25535 32985 39638 46178 51808 57894
400 524 671 809 927 1038 1164 106 29800 38160 46008 52718 59031 66197
500 577 730 881 1009 1129 1280 132 32814 41515 50102 57382 64206 72793
600 615 777 940 1078 1208 1383 159 34975 44188 53458 61306 68699 78651
700 650 817 991 1139 1280 1479 185 36965 46463 56358 64775 72793 84111
800 678 852 1037 1196 1347 1569 211 38558 48453 58974 68016 76604 89229
833 686 863 1050 1213 1368 1597 220 39013 49079 59713 68983 77798 90821

kPa psi


162
14 80
60° 140°
70
12

49° 120°
60
10
38° 100°
50
8
27° 81°
40
6 16° 61°
30
4
20
2 10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 315 405 495 580 670 – 55 17914 23032 28151 32985 38103 –
300 381 490 599 703 812 – 79 21667 27866 34065 39980 46178 –
400 439 565 690 810 935 – 106 24966 32131 39240 46065 53173 –
500 484 622 760 891 1029 – 132 27525 35373 43221 50671 58519 –
600 522 671 821 962 1112 – 159 29686 38160 46690 54709 63239 –
700 553 710 868 1018 1176 – 185 31449 40378 49363 57894 66879 –
800 575 739 903 1059 1223 – 211 32700 42027 51354 60225 69552 –
833 586 753 920 1079 1247 – 220 33326 42823 52320 61363 70917 –

kPa psi


163
14 80
60° 140°
12 70
49° 120°

60
10
38° 100°
30° 50 86°
8
16° 61°
40
6 5° 41°
30
4
20
2
10
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 338 412 486 540 631 691 55 19222 23430 27639 30710 35885 39297
300 401 489 577 641 749 820 79 22805 27809 32814 36454 42596 46633
400 459 559 659 729 855 939 106 26103 31790 37477 41458 48624 53401
500 500 612 720 800 934 1024 132 28435 34804 40946 45496 53116 58235
600 537 654 771 856 1000 1097 159 30539 37193 43847 48681 56870 62386
700 567 692 815 906 1058 1160 185 32245 39354 46349 51524 60168 65969
800 594 724 855 950 1110 1217 211 33781 41174 48624 54026 63126 69211
833 600 731 867 964 1125 1235 220 34122 41572 49306 54823 63979 70234

kPa psi


164
8 45
60° 140°
7 40

49° 120°
35
30
5
38° 100°
25
4 27° 81°
20
3
15
16° 61°
2
10
1 5° 5 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 50 129 212 267 352 400 55 2843 7336 12056 15184 20018 22748
300 60 153 252 315 419 477 79 3412 8701 14331 17914 23828 27127
400 67 170 280 360 474 542 106 3810 9668 15924 20473 26956 30823
500 75 192 316 395 520 596 132 4265 10919 17971 22464 29572 33894
600 81 207 340 424 558 636 159 4606 11772 19336 24113 31733 36169
700 85 217 356 450 590 673 185 4834 12341 20246 25591 33553 38273
800 89 229 376 470 622 708 211 5061 13023 21383 26729 35373 40264
833 90 231 380 475 630 717 220 5118 13137 21611 27013 35828 40776

kPa psi


165
5 30
38°
100°
25

4
20
30°
3 86°
15
2
10
16° 61°
1
5
5° 41°
0 0
0 200 400 600 800 1000 0 50 100 150 200 250

208 – – 24 81 181 262 55 – – 1365 4606 10293 14900
300 – – 29 96 215 310 79 – – 1649 5460 12227 17630
400 – – 32 108 242 350 106 – – 1820 6142 13763 19904
500 – – 35 117 264 381 132 – – 1990 6654 15014 21667
600 – – 37 124 280 404 159 – – 2104 7052 15924 22975
700 – – 39 130 293 423 185 – – 2218 7393 16663 24056
800 – – 41 135 304 439 211 – – 2332 7677 17288 24966
833 – – 41 137 307 444 220 – – 2332 7791 17459 25250

kPa psi


166
Heat Exchanger Data Groups 3N-8888, 3N-8889, 4W-4632, 107-1729
0.30 0.3
0.25 0.25
Heat Transfer Capacity, Btu/min
Heat Transfer Capacity, kW

0.20 0.2
0.15 0.15
0.10 0.1
0.05 0.05
0 0
0 50 100 150 200 250 300 350 400 0 200 400 600 800 1000 1200
Cooling Water Flow, gal/min Cooling Water Flow, L/min
3N-8888 3N-8889 4W-4632 107-1729 Effectiveness 3N-8888 3N-8889 4W-4632 107-1729 Effectiveness
Coolant Flow JW Flow (gpm) Coolant Flow JW Flow (L/min)
gpm 150 200 250 300 350 400 450 L/min 568 757 946 1136 1325 1514 1703
50 0.152 0.118 0.096 0.082 0.071 0.063 0.055 189 0.152 0.118 0.096 0.082 0.071 0.063 0.055
75 0.177 0.14 0.115 0.098 0.085 0.075 0.067 284 0.177 0.14 0.115 0.098 0.085 0.075 0.067
100 0.199 0.157 0.131 0.112 0.096 0.085 0.076 379 0.199 0.157 0.131 0.112 0.096 0.085 0.076
125 0.216 0.172 0.143 0.122 0.105 0.094 0.084 473 0.216 0.172 0.143 0.122 0.105 0.094 0.084
150 0.23 0.183 0.153 0.131 0.114 0.102 0.091 568 0.23 0.183 0.153 0.131 0.114 0.102 0.091
175 0.241 0.193 0.16 0.139 0.12 0.108 0.096 662 0.241 0.193 0.16 0.139 0.12 0.108 0.096
200 0.25 0.2 0.167 0.145 0.127 0.113 0.101 757 0.25 0.2 0.167 0.145 0.127 0.113 0.101
225 0.258 0.207 0.173 0.15 0.131 0.117 0.105 852 0.258 0.207 0.173 0.15 0.131 0.117 0.105
250 0.264 0.213 0.177 0.154 0.135 0.12 0.109 946 0.264 0.213 0.177 0.154 0.135 0.12 0.109
275 0.269 0.217 0.18 0.157 0.138 0.123 0.111 1041 0.269 0.217 0.18 0.157 0.138 0.123 0.111
300 0.273 0.22 0.183 0.16 0.14 0.125 0.113 1136 0.273 0.22 0.183 0.16 0.14 0.125 0.113
167
0.35 0.35
0.30 0.3
0.25 0.25

0.20 0.2
0.15 0.15
0.10 0.1
0.05 0.05
0 0
0 50 100 150 200 250 300 350 400 0 200 400 600 800 1000 1200
gpm 150 200 250 300 350 400 450 L/min 568 757 946 1136 1325 1514 1703
50 0.178 0.139 0.114 0.098 0.085 0.075 0.067 189 0.178 0.139 0.114 0.098 0.085 0.075 0.067
75 0.214 0.166 0.137 0.118 0.103 0.091 0.082 284 0.214 0.166 0.137 0.118 0.103 0.091 0.082
100 0.24 0.189 0.157 0.135 0.118 0.105 0.094 379 0.24 0.189 0.157 0.135 0.118 0.105 0.094
125 0.26 0.206 0.172 0.149 0.131 0.116 0.104 473 0.26 0.206 0.172 0.149 0.131 0.116 0.104
150 0.277 0.222 0.185 0.16 0.141 0.125 0.113 568 0.277 0.222 0.185 0.16 0.141 0.125 0.113
175 0.29 0.234 0.196 0.17 0.15 0.134 0.12 662 0.29 0.234 0.196 0.17 0.15 0.134 0.12
200 0.301 0.243 0.205 0.177 0.156 0.14 0.126 757 0.301 0.243 0.205 0.177 0.156 0.14 0.126
225 0.31 0.251 0.212 0.183 0.162 0.145 0.131 852 0.31 0.251 0.212 0.183 0.162 0.145 0.131
250 0.317 0.257 0.218 0.188 0.167 0.149 0.135 946 0.317 0.257 0.218 0.188 0.167 0.149 0.135
275 0.323 0.262 0.222 0.192 0.17 0.152 0.138 1041 0.323 0.262 0.222 0.192 0.17 0.152 0.138
300 0.327 0.266 0.225 0.195 0.173 0.155 0.14 1136 0.327 0.266 0.225 0.195 0.173 0.155 0.14
168
0.40 0.40
0.35 0.35
0.30 0.30

0.25 0.25
0.20 0.20
0.15 0.15
0.10 0.10
0.05 0.05
0 0
0 50 100 150 200 250 300 350 400 0 200 400 600 800 1000 1200
gpm 150 200 250 300 350 400 450 500 L/min 568 757 946 1136 1325 1514 1703 1893
50 0.195 0.157 0.128 0.109 0.095 0.084 0.074 0.068 189 0.195 0.157 0.128 0.109 0.095 0.084 0.074 0.068
75 0.235 0.191 0.158 0.134 0.117 0.104 0.093 0.085 284 0.235 0.191 0.158 0.134 0.117 0.104 0.093 0.085
100 0.267 0.217 0.18 0.155 0.136 0.121 0.108 0.099 379 0.267 0.217 0.18 0.155 0.136 0.121 0.108 0.099
125 0.292 0.238 0.199 0.172 0.151 0.135 0.122 0.11 473 0.292 0.238 0.199 0.172 0.151 0.135 0.122 0.11
150 0.309 0.255 0.215 0.185 0.163 0.146 0.132 0.12 568 0.309 0.255 0.215 0.185 0.163 0.146 0.132 0.12
175 0.325 0.268 0.227 0.197 0.173 0.155 0.141 0.128 662 0.325 0.268 0.227 0.197 0.173 0.155 0.141 0.128
200 0.338 0.28 0.237 0.205 0.182 0.163 0.148 0.135 757 0.338 0.28 0.237 0.205 0.182 0.163 0.148 0.135
225 0.347 0.29 0.245 0.213 0.189 0.17 0.153 0.14 852 0.347 0.29 0.245 0.213 0.189 0.17 0.153 0.14
250 0.356 0.297 0.252 0.219 0.195 0.175 0.158 0.145 946 0.356 0.297 0.252 0.219 0.195 0.175 0.158 0.145
275 0.364 0.303 0.257 0.224 0.2 0.179 0.162 0.149 1041 0.364 0.303 0.257 0.224 0.2 0.179 0.162 0.149
300 0.37 0.308 0.261 0.228 0.204 0.182 0.165 0.152 1136 0.37 0.308 0.261 0.228 0.204 0.182 0.165 0.152
169
Suppliers of Marine Control Systems
Equipment Description Supplier Address Person to Contact at Supplier
Marine Engine Controls Mathers Controls Incorporated Harold Mathers
675 Please Road Founder
Burlington, Washington 98233
United States of America
Phone: 360-757-1100
Fax: 360-757-2500
TD Electronics Bob Bertolasi
6815 Elm Avenue General Manager
Loves Park, IL 61111-3818
United States of American
Phone: 815-633-9232
Fax: 815-633-9272
170
®
LEBM7301 ©1997 Caterpillar Inc. Printed in U.S.A.

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3500B Engines

This data contained herewith can be used for preliminary design.

3516B Package Gen Set with Low NOx Emissions 123-3180

3508 Optional Generators 125-7852

3512 Optional Generators 125-7851

3516 Optional Generators 125-0710

3508 Prime and Continuous with FC60 Radiator 106-2090

3508 Prime with FC50 Radiator and 125-3444

3508 Prime and Continuos with 690 Frame 125-3445

3508 Standby w/FC60 and 72 Radiator with 690 125-3446

3512 Prime, Standby & Continuos with all 108-2091

3516 Prime, Standby with 46CV Radiator and 105-2900

3516 Prime, Continuos & Standby w/FC72 Rad and 4P-3853

3516 Prime, Continuos FC60 & 72 Radiators and 9Y-4535

3516 Prime Power with Kato Generator 104-8652

3516 Standby Power with Kato Generator 100-8748

3516 Prime, Continuos & Standby FC72 Radiator 125-0708

3512B Package Generator Set - Prime 126-5091

3508B Package Generator Set - Standby 126-5088

3508B Package Generator Set - Prime 126-5089

3516B SCAC Marine Engine - Heavy Weight 120-4499

3512B Marine Engine - Heavy Weight 115-3615

3508B Marine Engine - Heavy Weight 110-2754

3516B SCAC Marine Engine - Light Weight 125-6281

3512B Marine Engine - Light Weight 115-3610

3508B Marine Engine - Light Weight 116-8022

3516B SCAC Marine Auxiliary 125-6280

3512B Marine Auxiliary 125-6279

3508B Marine Auxiliary 125-6278

Troubleshooting - 3500B EPG Diesel Engines SENR1003

Troubleshooting - 3500B EPG with EMCP-II SENR1004

Troubleshooting - 3500B EPG with Switchgear Conversion SENR1005

Specifications - 3500B EPG&Marine Engines SENR6562

3500B Marine Engine Systems Operation, Testing and Adjusting SENR6563

Disassembly & Assembly Manual - Marine and Gen Set SENR6564

EPG Load Sensor and Load Sharing Module SENR6565

Service Manual - 3500B Electronic Instrument Panel SENR6587

Programmable Relay Control Panel (PRCM) SENR6588

Service Manual for SR4B Generator SENR8395

3500B Operation and Maintenance - (EPG) SEBU6916

Operation and Maintenance (Marine Engines) SEBU6917

Operation and Maintenance - (SR4B) SEBU6918

Troubleshooting - 3500 Marine Diesel Engines SENR1008

Troubleshooting - 3500 Marine Propulsion (Dual ECM) SENR1009

Troubleshooting - 3500 Marine Auxiliary SENR1010

Customer Communications Module for (EMCPII) Owners Manual SEBU6874

Digital Voltage Regulator SENR5833

Woodward Load Sharing Governor Module SENR6501

DeNox Service Manual SENR1007

Harness Wire Identification ......................................11 Connecting Basic Pilot House Panel

Wiring Diagrams / Harnesses ....................................49

1. Contact the PC hotline at 1-800-THE-PCDR (843-7237)

In addition to only eleven basic colors of wire, a

The operator will use the PRCM Keypad and Display

Note: Do not connect terminals 1, 2, 12 or 40

Note: Only one Remote Start/Stop Switch is

Note: Using this Sensor, the operator can also

The calibration of the throttle position sensor

Adjustment at High Idle Stop Position

Repeat the adjustment at LOW IDLE position to

• Turn ECS (Engine Control Switch) to OFF

Purpose LCD Display

Warning Indicator Lights