Caterpillar 3512 Engine Technical Data PDF

(i Barloworld CAT
“35
Finanzaauto
G3512 ENGINES
FG750LD
SUPPLY RANGE
STANDARD
v. 06/05
INDEX
(i Barloworld CAT
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Finanzaauto
1 THE G3500 ENGINES............................................................................................................8

2 TECHNICAL DATA OF THE MOTORGENERATOR......................................................10
2.1 Powers, performances and emissions.........................................................................12
2.2 Approximate dimensions and weights........................................................................13
2.2.1 Dimensions..........................................................................................................13
2.2.2 Pesos....................................................................................................................14
2.2.2.1 Engine-alternator.........................................................................................14
2.2.2.2 Group components.......................................................................................14
2.3 Sound levels................................................................................................................15
2.3.1 Sound pressure of mechanical origin at 100% load............................................15
2.3.2 Sound pressure due to exhaust gases at 100% load............................................15
3 ENGINE.................................................................................................................................16
3.1 Block...........................................................................................................................16
3.2 Pistons.........................................................................................................................16
3.3 shirts...........................................................................................................................16
3.4 Crankshaft...................................................................................................................16
3.5 camshaft......................................................................................................................16
3.6 Cylinders.....................................................................................................................17
3.7 Cranks.........................................................................................................................17
4 INTAKE SYSTEM............................................................................................................18
4.1 air filter housing.........................................................................................................18
4.2 Air filter......................................................................................................................18
4.3 Service indicator.........................................................................................................18
4.4 Turbocharger..............................................................................................................18
4.5 Technical specification...............................................................................................18
4.5.1 Allowable restriction...........................................................................................18
4.5.2 Flow.....................................................................................................................18
4.6 Installation guide........................................................................................................18
5 EXHAUST SYSTEM........................................................................................................19
5.1 Exhaust manifolds......................................................................................................19
5.2 By-pass valve..............................................................................................................19
5.3 Flexible connection....................................................................................................19
5.4 Expander.....................................................................................................................19
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5.5.1 Flow rates, temperature and available thermal power........................................20
5.5.2 gas emissions.......................................................................................................20
5.5.3 Minimum exhaust system requirements..............................................................20
5.6 Installation Guide............................................................................................................21
6 COOLING SYSTEM.............................................................................................................21
6.1 High Temperature Circuit (HT)..................................................................................21
6.1.1 Water Pump.........................................................................................................21
6.1.2 Thermostatic valve..............................................................................................21
6.1.3 Automatic purge valve........................................................................................22
6.1.4 Flexible connections............................................................................................22
6.1.5 Instrumentation...................................................................................................22
6.1.6 Antifreeze and anticorrosive...............................................................................22
6.2 Low Temperature Circuit (LV)..................................................................................23
6.2.1 Air aftercooler.....................................................................................................23
6.2.2 oil cooler..............................................................................................................23
6.2.3 Flexible connections............................................................................................23
6.2.4 Automatic purge valve........................................................................................23
6.2.5 Thermostatic Valve (loose supply).....................................................................23
6.3.1 High Temperature Circuit...................................................................................23
6.3.2 Low Temperature Circuit..........................................................................................24
6.3.3 Engine coolant characteristics..................................................................................25
7 LUBRICATION SYSTEM................................................................................................27
7.1 Oil pump.....................................................................................................................27
7.2 Oil filters.....................................................................................................................27
7.3 oil cooler.....................................................................................................................27
7.4 Wet sump....................................................................................................................27
7.5 Crankcase breathers....................................................................................................27
7.6 Crankcase ventilation air filter...................................................................................27
7.7 Automatic oil level control.........................................................................................28
7.8 Oil dipstick.................................................................................................................28
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7.9 Oil...............................................................................................................................28
7.10 CEAD Program..........................................................................................................28
7.11.1 Crankcase capacity..............................................................................................28
7.11.2 Consumption.......................................................................................................28
7.11.3 Specifications of the oil to use............................................................................28
7.12 Oil characteristics.......................................................................................................29
8 FUEL SYSTEM.................................................................................................................29
8.1 Gas ramp.....................................................................................................................29
8.2 Flexible connection....................................................................................................30
8.3 Venturi type carburetor...............................................................................................30
8.4 Butterfly valve............................................................................................................30
8.5 TecJet fuel control system..........................................................................................30
9 STARTING SYSTEM...........................................................................................................33
9.1 Starting motor.............................................................................................................33
9.2 Batteries......................................................................................................................33
9.3.1 Batteries...............................................................................................................33
10 IGNITION SYSTEM...........................................................................................................34
10.1 Control Module (EISM).............................................................................................34
10.2 Sensors........................................................................................................................34
10.3 Transformers...............................................................................................................34
10.4 Plugs...........................................................................................................................34
10.5 Cabling.......................................................................................................................35
11 ALTERNATOR...................................................................................................................35
11.1 Technical specification..................................................................................................36
11.2 Installation Guide..........................................................................................................38
12 SPEED AND POWER CONTROL SYSTEM....................................................................38
13 INSTRUMENTATION..................................................................................................39
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13.1 Instruments panel........................................................................................................39

14 PROTECTION SYSTEM..............................................................................................40
14.1 Engine protection system...........................................................................................40
14.2 Alternator protection system.........................................................................................43
15 BASIC CHART OF COGENERATION.............................................................................43
15.1 Metal carpentry...........................................................................................................43
15.2 Equipment...................................................................................................................44
15.2.1 Control PLC........................................................................................................44
15.2.1.1 Group control...............................................................................................44
15.2.1.2 Alarm control...............................................................................................45
15.2.2 Graphic Operator Terminal.................................................................................45
15.2.3 Protections...........................................................................................................45
15.2.3.1 Engine..........................................................................................................45
15.2.3.2 Generator.....................................................................................................46
15.2.3.3 Tie rods........................................................................................................49
15.2.4 Synchronizer.......................................................................................................49
15.2.5 Extent..................................................................................................................49
15.2.5.1 Generator.....................................................................................................49
15.2.5.2 Synchronization...........................................................................................50
15.2.5.3 Engine..........................................................................................................50
15.2.6 Signaling.............................................................................................................50
15.2.7 Pushbuttons and selectors...................................................................................50
15.2.7.1 Generator switch closure.............................................................................51
15.2.7.2 Generator switch opening............................................................................51
15.2.8 Converters...........................................................................................................51
15.2.9 Auxiliaries...........................................................................................................51
15.2.9.1 General AC power.......................................................................................51
15.2.9.2 Battery charging system...............................................................................51
15.2.9.3 Engine heating system.................................................................................52
15.2.9.4 Generator heating system.............................................................................52
15.2.9.5 Gas train system...........................................................................................52
15.2.9.6 Power supply and panel lighting system......................................................52
15.3 Observations..................................................................................................................52
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16 VENTILATION...................................................................................................................54
16.1 Room ventilation........................................................................................................54
16.2 Crankcase ventilation.................................................................................................55
17 MOUNTING SYSTEM.......................................................................................................57
17.1 Common steel engine-alternator bench......................................................................57
17.2 Anti-vibration pads.....................................................................................................57
18 STEERING WHEEL ASSEMBLY...............................................................................58
18.1 flywheel......................................................................................................................58
18.2 Case............................................................................................................................58
18.3 Vibration damper........................................................................................................58
19 ACCESSORIES.............................................................................................................59
19.1 Lifting eyes.................................................................................................................59
19.2 Identification signs.....................................................................................................59
19.3 Plastic protection........................................................................................................59
19.4 Documentation...........................................................................................................59
20 OPTIONAL....................................................................................................................59
20.1 Exhaust system...........................................................................................................59
20.1.1 Silent...................................................................................................................59
20.1.1.1 Description...................................................................................................59
20.1.1.2 Technical specification................................................................................60
20.2 Refrigeration system...................................................................................................60
20.2.1 Heating resistors..................................................................................................60
20.3 Fuel system.................................................................................................................60
20.3.1 CH 4 Analyzer.....................................................................................................60
20.4 Lubrication system.....................................................................................................61
20.4.1 Crankcase filling/draining pump.........................................................................61
20.4.2 Crankcase exhaust fan.........................................................................................61
20.5 Speed and power control system................................................................................63
20.5.1 Load sharing module...........................................................................................63
20.6 Control Box................................................................................................................63
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20.7 Accessories.................................................................................................................64
20.7.1 Toolbox...............................................................................................................64
20.8 Transport.....................................................................................................................64
21 REGULATIONS, QUALITY AND SAFETY..............................................................64
21.1 Thermal and acoustic insulation.................................................................................64
21.1.1 Thermal isolation:...............................................................................................64
21.1.2 Acoustic isolation................................................................................................64
21.2 Emissions and discharges...........................................................................................64
21.3 Electricity...................................................................................................................64
21.4 Paint............................................................................................................................64
21.5 Protections and security..............................................................................................64
21.6 Regulations and quality..............................................................................................64
21.7 Factory tests................................................................................................................65
22 START UP.....................................................................................................................65
23 CATERPILLAR WARRANTY: GENERATING SET.................................................65
23.1 Warranty period..........................................................................................................65
23.2 Caterpillar Obligations...............................................................................................66
23.3 Client Obligations.......................................................................................................66
23.4 Restrictions.................................................................................................................66
23.5 Warranty term.............................................................................................................67
24 ANNEXES...........................................................................................................................67
2
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GRADES:
1) All data in this document has been verified and is correct at the date of printing.
FINANZAUTO SA reserves the right to modify any data without prior notice.
2) All pressures that appear in this document are relative
3) The cover and page 8 photographs do not correspond exactly to the standard supply
1 THE G3500 ENGINES
Despite the growing concern to improve air quality and reduce atmospheric pollution as much
as possible, energy generation, a process that is generally highly polluting, remains essential
in today's world.
With a constant concern for air quality, Caterpillar has created the G3500 family that operates
according to the lean burn principle. This principle is based on the use of an air-fuel ratio
greater than the stoichiometric one. The excess air minimizes the formation of NOx during
combustion, so that the Caterpillar G3500 lean burn engines comply with the strictest
regulations on NOx emissions currently in force.
In addition to the undeniable environmental advantages of using lean mixture, the G3500
family has Caterpillar's own Electronic Ignition Module (EISM) as well as a special open
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combustion chamber design that allows for greater power and better performance.
Within the G3500 engine family, Caterpillar has several models, each of which has been
specifically designed to work with a certain type of gas: natural gas, propane, biogas and
landfill gas.
Along with the above, we must not forget that gaseous fuels are cleaner and have better
availability than other fuels. Likewise, when using a renewable energy source, such as biogas
or landfill gas, a fuel that would otherwise be wasted is used. In this way, using Caterpillar
G3500 engines not only saves money, but also contributes to the protection of the
environment.
All this, together with Caterpillar's high technology in the development of the components of
its gas engines, makes the G3500 family
the natural choice!
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2 TECHNICAL DATA OF THE MOTORGENERATOR
MODEL FG750LD
Engine G3512 TA
Alternator SR4B brushless, 962.5 kVA 400 V
Brake horsepower 803 bkW
Electrical power (cos ϕ = 1) 780 ekW
Setting 12 cylinders in V at 65º
Bore x Stroke 170x190mm
Displacement 51.8 liters
Compression ratio 12:1
Speed 1500RPM
Ignition sequence 1-12-9-4-5-8-11-2-3-10-7-6
Rotation CCW. SAE standard
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Motorgenerator manufactured according to ISO 9001 quality standards
Finanza
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2.1 Powers, performances and emissions
ENGINE SPEED (RPM) 1500 11:1 FUEL Landfill Gas/Biogas

COMPRESSION RATIO 54 PCI GAS (MJ/Nm 3 ) 22,2
AFTERCOOLER INLET MINIMUM METHANE NO. 130
WATER OUTLET TEMPERATURE 110 CH4 (%) 46-70
FROM SHEETS
IGNITION (ºC)
SYSTEM EIS ALTITUDE (m) 500
MANIFOLD WET ATM TEMPERATURE (ºC) 25
ALTERNATOR RTO (cos
POWER AND PERFORMANCE
ϕ 97,1
100 % 75% 50%
BRAKE HORSEPOWER bkW 803 602 402

ekW 780 583 386
ELECTRICAL POWER (cos =1)
ENGINE PERFORMANCE
ϕ % 33,0 30,1 27,6
ELECTRICAL PERFORMANCE % 32,0 29,1 26,5
ENGINE DATA
FUEL CONSUMPTION MJ/bkWh 10,91 11,96 13,04
VOLUMETER AIR FLOW Nm 3 /bkWh 3,66 3,87 4,61
AIR MASS FLOW kg/bkWh 4,73 5,00 5,95
PRESSURE IN INTAKE MANIFOLD KPAa 222 176 161
INTAKE MANIFOLD TEMPERATURE ºC 55 52 50
TIMING ºBTDC 20 20 20
EXHAUST TEMPERATURE ºC 486 480 471
3
VOLUME FLOW EXHAUST GASES (WET) Nm /bkWh 4,26 4,51 5,38
EXHAUST GASES MASS FLOW (WET) kg/bkWh 5,32 5,64 6,72
EMISSIONS
NO x (as NO 2 ) (corr. 5% O 2 ) mg/Nm 3 500 500 500
CO (corr. 5% O 2 ) mg/Nm 3650 1145 1078 1316
HCT (corr. 5% O 2 ) mg/Nm 3 1435 1652 1899
HCNM (corr. 5% O 2 ) mg/Nm 3 216 248 285
Or 2 % 6,3 6,3 6,1
THERMAL BALANCE
PCI FUEL CONSUMPTION kW 2434 2001 1455
POT. THERMAL WATER SHIRTS kW 632 593 426
POT. THERMAL OIL KW 132 124 89
POT. AFTERCOOLER THERMAL kW 92 65 49
ENGINE RADIATION kW 90 75 60
POT. THERMAL EXHAUST (PCI AT 25ºC) kW 686 544 429
POT. THERMAL EXHAUST (PCI AT 120ºC) kW 518 406 315
Note: data according to specification sheet DM0761 (11-Jul-02)
TOLERANCES
PCI consumption: + 5%
Thermal power in jacket water, oil and exhaust gases: ± 8%
Thermal power in aftercooler: ± 8%
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Engine Radiation: ±25%
GRADES
1. Continuous power and reference conditions according to ISO 3046/1 standard: Temperature: 25
ºC, pressure: 1000 mbar.
2. Electrical power for an alternator efficiency of 97.1% and cos ϕ=1 Electrical power = engine
power x alternator efficiency
3. Emissions measured in dry exhaust gases and referenced to 5% O 2 .
4. Total performance = Electrical performance + Thermal performance
5. The indicated power values are valid under standard conditions. For different
conditions, apply the attached detachment factor:
0m 250m 500m 750m 1000m 1250m 1500m 1750m 2000m
50ºC 0,98 0,95 0,92 0,89 0,87 0,84 0,81 0,79 0,76
45ºC 1 0,97 0,94 0,91 0,88 0,85 0,83 0,80 0,77
40ºC 1 0,98 0,95 0,92 0,89 0,87 0,84 0,81 0,79
35ºC 1 1 0,97 0,94 0,91 0,88 0,85 0,83 0,80
30ºC 1 1 0,98 0,95 0,92 0,89 0,87 0,84 0,81
25ºC 1 1 1 0,97 0,94 0,91 0,88 0,85 0,83
20ºC 1 1 1 0,99 0,96 0,93 0,90 0,87 0,84
15ºC 1 1 1 1 0,97 0,94 0,91 0,88 0,85
10ºC 1 1 1 1 0,99 0,96 0,93 0,90 0,87
6. G3500 motors are designed to operate at 100% load although they can operate at partial loads as
long as the following is not exceeded:
- 0 to 30% for 30 minutes
- 31 to 50% for 2 hours
- 51 to 100% continuous operation
In any case, after low load operation, the engine must be operated for a minimum of two hours
with a load factor of more than 70%.
7. For the technical data included in this section to be valid, it is necessary that the gas meets the
requirements indicated in point 8.6 of this document. Values different from those shown must be
studied by Finanzauto, SA to calculate the engine performance and the feasibility of operation in
different conditions.
2.2 Approximate dimensions and weights
2.2.1 Dimensions
Width: 2160mm (2671 with filter service)
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Height (including vibration dampers and exhaust expander): 2245 mm
Length (engine-alternator): 4565mm
2.2.2 Pesos
2.2.2.1 Engine-alternator
Dry weight: 11500 kg
Weight with liquids: 12000 kg
2.2.2.2 Group components

Crankshaft: 561kg
Steering wheel: 155kg
Alternator 3400kg
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2.3 Sound levels

2.3.1 Sound pressure of mechanical origin at 100% load
1.0m 7.0m 15.0m

63Hz (dB) 93 83 77
125Hz (dB) 94 84 79
250Hz (dB) 91 81 75
500Hz (dB) 89 79 73
1000Hz (dB) 92 82 76
2000Hz (dB) 92 82 76
4000Hz (dB) 88 78 72
8000Hz (dB) 82 72 67
Overall (dB(A)) 100 87 81
2.3.2 Sound pressure due to exhaust gases at 100% load
1.5m 7.0m 15.0m

63Hz (dB) 102 87 80
125Hz (dB) 106 95 88
250Hz (dB) 108 93 86
500Hz (dB) 105 91 84
1000Hz (dB) 106 93 87
2000Hz (dB) 106 92 86
4000Hz (dB) 106 93 86
8000Hz (dB) 103 88 82
Overall (dB(A)) 113 99 93
Note: the sound pressure data are given in the center frequencies of the different octave bands (dB)
and according to filter A (dB(A)).
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3 ENGINE
Like all Caterpillar products, the G3512 biogas/landfill gas engine has been designed for use in
extremely harsh conditions for many years.
3.1 Block
It is built in a single piece of gray cast iron. After
molding, it is subjected to a stress process that
provides its subsequent dimensional invariance and
an increase in the breaking limit. The cylinders are
arranged in a V shape with an angle of 60º; In this
way, the width of the block is minimal.
3.2 Pistons
They have been specially designed for lean-burn natural gas engines by lengthening their edges so
that, while achieving an increase in the compression ratio, the formation of turbulence in the area of
the crown perimeter is facilitated, an effect that allows rapid ignition of the mixture. In addition, the
crown has been transformed into a domed one to reduce the distance to travel along the flame front
and thus achieve a more complete combustion.
3.3 shirts
They are wet type, easily removable, made of Cr-Mo-Cu steel.
3.4 Crankshaft
It is manufactured from forged steel with subsequent treatment to give it a surface hardness that
prevents wear due to friction. It has 7 steel-reinforced light alloy main bearings, and counterweights
that balance the assembly, minimizing vibrations and bending.
3.5 camshaft
It is located in the upper part, near the stock so that the transmission of movement is shorter and the
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mechanism more rigid.
3.6 Cylinders
Each cylinder has its own independent cylinder head. The intake duct is short and independent and
part of a common manifold, which allows a single carburetion and fuel pressure regulation, thus
facilitating the calibration and maintenance of the fuel system and the engine in general. The design of
the cylinder head achieves perfect cooling of the valves and the spark plug, located in a central
position. Each cylinder head has four valves, two intake and two exhaust, with positive rotation that
prevents overheating and occasional wear of the valves. Their seat is made of high temperature
resistant nickel alloy.
The cylinder head elements in these engines have been manufactured with materials especially
resistant to corrosion by biogas acids.
3.7 Cranks
They are made of cast steel, hardened and tempered.
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4 INTAKE SYSTEM
The air intake system is made up of two identical units arranged on either side of the engine. Each unit
incorporates the following elements:
4.1 air filter housing
Cylindrical, made of steel. It is joined to the engine by flexible joints that isolate it from vibrations.
4.2 Air filter

Based on dry paper elements, capable of removing up to 99.5% of suspended particles.
4.3 Service indicator
By measuring differential pressure before and after the filter, it indicates the appropriate time to
change the filter, which allows optimizing its life.
4.4 Turbocharger
Consisting of an intake air compressor driven by a turbine driven by the energy of the exhaust gases.
These turbines are large in size, thereby reducing the pressure in the exhaust manifold, thus obtaining
less remaining heat in the pistons and therefore an increase in the detonation margin and an
improvement in specific consumption and performance. The turbocharger elements in contact with the
exhaust gases are made of stainless steel.
4.5 Technical specification
4.5.1 Allowable restriction
• Maximum design restriction in the intake including dirty filters, ducts and negative pressure in the
room: 38 mbar.
• The maximum recommended restriction in the design of the intake system is 13 mbar (includes
restriction of the clean filter, ducts and back pressure in the room). This provides a filter fouling
reserve of 25 mbar, sufficient to optimize their life. A restriction greater than that indicated has a
negative impact on the life of the filters.
• Restriction of clean Caterpillar filters: 8 mbar
4.5.2 Flow
The air flow required for the admission and correct combustion of fuel at 100% load is 2939 Nm 3 /h
per engine.
4.6 Installation guide

• During any assembly or disassembly of the filters, the air inlet duct to the turbo must be protected
to prevent particles from entering it.
• Before starting the engine, the filter must be removed and check that the turbocharger shell is clean
and free of obstructions.
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5 EXHAUST SYSTEM
It is made up of the following elements:
5.1 Exhaust manifolds

The two wet exhaust manifolds are made up of three concentric chambers: the inner one houses the
exhaust gases, the intermediate one air and the outer one water. With this arrangement, it is possible to
slightly reduce the temperature of the exhaust gases while limiting engine radiation. The material
inside the manifold in contact with the exhaust gases is stainless steel, to avoid corrosion.
5.2 By-pass valve

The exhaust gas by-pass valve is a diaphragm valve whose function is to regulate the amount of
exhaust gas that passes through the turbo to control the maximum pressure in the intake manifold.
5.3 Flexible connection

Made of stainless steel, 203 mm in diameter and 305 mm in length. Finished on both sides with
flanges with eight bolts each. Supplied loose.
5.4 Expander
From 203mm to 305mm. Includes gaskets, flange and counterflange on the largest diameter outlet
where the rest of the customer's installation is connected. Supplied loose.
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5.5.1 Flow rates, temperature and available thermal power
% Burden 100% 75 % 50%

686 544 429
Pot. Exhaust thermal (PCI 25 ºC) (kW)
518 406 315
Pot. Thermal exhaust (PCI 120 ºC) (kW)
489 480 471
Exhaust gas temperature (ºC)
Exhaust gas flow (wet) (Nm 3 /h) 3421 2715 2163
Exhaust gas mass (wet) (kg/h) 4272 3395 2701
5.5.2 gas emissions
% Burden 100 % 75 % 50 %
500 500 500
NO x (as NO 2 ) 5% O 2
(mg/Nm 3 )
1145 1078 1316
CO 5% O 2 (mg/Nm 3 )
1435 1652 1899
HCT 5% O 2 (mg/Nm 3 )
216 248 285
HCNM 5% O 2 (mg/Nm 3 )
6,3 6,3 6,1
Or 2 dry (%)
Grades:
1) HCNM: Hydrocarbons without methane
HCT: Total hydrocarbons
2) Emission values referred to dry exhaust gases
5.5.3 Minimum exhaust system requirements
• Maximum allowable exhaust backpressure: 67 mbar.
• Exhaust design backpressure: 50 mbar
• Maximum allowable deformations in the flexible connection:
- Maximum deviation between flange centers: 19.05 mm
- Maximum compression: 38.1mm
- Maximum expansion: 25.4mm
Maximum deformations are not cumulative
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5.6 Installation Guide
• The supply ends at the engine exhaust expander flange. The customer must connect to said flange
taking into account that none of the elements of the exhaust system must rest on the flexible, and
therefore must provide a support structure for the elbow and exhaust silencer.
• In order to avoid problems with the evaluation of the room air cooling capacity and to obtain
greater thermal recovery in the exhaust gas system, all the elements that make up the exhaust
system must be perfectly heat-insulated.
• To prevent water condensed in the exhaust gases or rainwater from penetrating the inside of the
engine causing corrosion, it is recommended to install condensate traps at the lowest points of the
system as well as ending the chimney in a duckbill or using caps. in vertical exhaust outlets
depending on the pressure losses of the system.
• Although it may be economically tempting, common elements in the exhaust gas system for
several engines are not accepted by Caterpillar since if one of the equipment stops, it is
susceptible to gases passing from the unit in operation causing water condensation and corrosion
of the engine elements. Likewise, the returned gases can cause the turbos to rotate without
lubrication, causing them to seize. Dampers in exhaust ducts are not effective solutions since over
time they considerably lose their original tightness.
• In heat recovery systems it is not advisable to lower the temperature below 204ºC, in order to
avoid condensation and corrosion problems.
• To avoid corrosion due to condensation of corrosive components present in the exhaust gases, all
elements of the exhaust system, including heat recovery systems, must be resistant to corrosion.
Likewise, the exhaust silencer must be made of stainless steel.
6 COOLING SYSTEM
The engine cooling circuit is made up of the High Temperature circuit (jacket water) and the Low
Temperature circuit (oil and aftercooler).
6.1 High Temperature Circuit (HT)
Includes the following components:
6.1.1 Water Pump

Powered by the motor itself with gear drive, non-self-priming centrifuge.
The casing and impeller are cast iron; The front sealing part of the pump is ceramic and the shaft is
steel.
6.1.2 Thermostatic valve
Located at the exit of the circuit, its function is to control the minimum operating temperature of the
motor. It begins to open at 108ºC, being completely open at 120ºC.
Due to the mechanical inertia of the thermostatic valve components, the temperature fluctuations at the
secondary inlet of the jacket water cooling circuit cannot be very large (< 10ºC) since the
aforementioned valve will be incapable of absorbing these variations. so the engine will run the risk of
running overcooled or overheated (both situations are detrimental to the engine).
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6.1.3 Automatic purge valve
Located in the highest part of the circuit.
6.1.4 Flexible connections

Flexible connections including DN125 PN16 DIN2501 flanges, located at the entrance and exit of the
circuit, for connection with the customer's refrigeration circuit.
6.1.5 Instrumentation
• Water level detector
6.1.6 Antifreeze and anticorrosive
For the correct functioning of the cooling system, Finanzauto SA supplies the antifreeze and
anticorrosive for the first filling of the high temperature primary circuit. The amount of additives
necessary to obtain a maximum of 400 liters of coolant with 30% antifreeze and 6% anticorrosive is
supplied, with water being supplied by the customer.
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6.2 Low Temperature Circuit (LV)

6.2.1 Air aftercooler
Single stage tubular type heat exchanger to cool the intake air from the turbochargers. The body of the
aftercooler is made of stainless steel to prevent corrosion caused by the intake mixture.
6.2.2 oil cooler
Tubular heat exchanger in which the engine lubrication oil is cooled.
6.2.3 Flexible connections
Flexible connections finished with DN65 PN16 DIN 2501 flanges, located at the entrance and exit of
the circuit, for connection with the customer's refrigeration circuit.
6.2.4 Automatic purge valve
Located in the highest part of the engine circuit.
6.2.5 Thermostatic Valve (loose supply)
Loose supply of thermostatic valve for installation at the outlet of the circuit. Its function is to control
the minimum operating temperature of the engine. It begins to open at 57ºC, being completely open at
66ºC.
Due to the mechanical inertia of the thermostatic valve components, the temperature fluctuations at the
secondary inlet of the aftercooler refrigeration circuit cannot be very large (< 10ºC) since the
aforementioned valve will be incapable of absorbing these variations, therefore that the engine will be
at risk of running overcooled or overheated (both situations are detrimental to the engine).

6.3.1 High Temperature Circuit
• 100% thermal balance

- Total thermal power to be dissipated: 632 kW ( ±
- Nominal inlet temperature: 8%) 102ºC
- Maximum outlet temperature: 110ºC
- Maximum admissible thermal jump: 8ºC
The coolant liquid is 70% water+30% glycol (Cp:3.91 kJ/kgºC, Density: 1003 kg/m 3 )
• Pressures
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All pressure data are given for the design temperature at 100% load.
- Maximum pressure in the block: 3.79 bar
- Maximum pump suction pressure: 1.96 bar
- Recommended pressure range to pressurize he circuit: 1.6 -1.7 bar
- Available pressure drop in the external circuit toengine (see next graphic):
Flow rate
(l/min)
• Ability
The capacity of the engine high temperature circuit is 148 l.
6.3.2 Low Temperature Circuit
• 100% thermal balance

- Thermal power to be dissipated in aftercooler: 92 kW ( ± 8%)
- Thermal power to be dissipated in oil: 132 kW ( ± 8%)
- Total power to be dissipated: 224 kW ( ± 8%)
- Maximum admissible thermal jump: 8ºC
- Inlet temperature: 54ºC
Inlet temperatures lower than this value are not admissible in order to minimize corrosive
condensation in the intake manifold.
The coolant liquid is 70% water+30% glycol (Cp: 3,775 kJ/kgºC, Density: 1032 kg/m 3 )
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The thermal power values dissipated in the aftercooler are given at 150 m altitude and 25ºC. For
different altitude and temperature conditions, this thermal power is multiplied by a heat dissipation
factor, according to the following table:
Tª/ Altitude 0 m 250 m 500 m 750 m 1000 m 1250 m 1500 m 1750 m 2000 m
50ºC 1,41 1,47 1,53 1,53 1,53 1,53 1,53 1,53 1,53
45ºC 1,32 1,38 1,44 1,44 1,44 1,44 1,44 1,44 1,44
40ºC 1,23 1,29 1,35 1,35 1,35 1,35 1,35 1,35 1,35
35ºC 1,14 1,20 1,26 1,26 1,26 1,26 1,26 1,26 1,26
30ºC 1,06 1,11 1,17 1,17 1,17 1,17 1,17 1,17 1,17
25ºC 1 1,02 1,08 1,08 1,08 1,08 1,08 1,08 1,08
20º C 1 1 1 1 1 1 1 1 1
Taking these detaring factors into account, the total thermal power to be dissipated is:
Pot. Total = 92 kW x Tariff factor + 132 kW
• Pressures
All pressure data are given for the design temperature at 100% load.
- Maximum pressure at the inlet of the aftercooler: 2.76 bar
- Pressure loss in the internal circuit of the motor: 0.4 bar (for 460 l/min)
• Ability
The capacity of the low temperature circuit is 15 l.
6.3.3 Engine coolant characteristics
The water necessary for the engine cooling system must be demineralized and/or deionized. If this is
not possible, the following minimum specifications must be met:
ENGINE COOLANT CHARACTERISTICS

Silica 150 max
Total alkalinity ppm as SiO 2 ppm as CaCO 3 700 max
Specific conductivity µmho /cm 3500 max
Solid particles ppm 10 max.
It is recommended that the jacket water be treated as follows:

- Remove oxygen from water
- Maintain an equivalent alkalinity of 200-400 ppm (as CaCO3)
- Add the appropriate dispersants to condition and suspend the solids in the water until they
are eliminated by purging.
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If external water is used, the following specifications must be met:
Iron ppm 0.1max

Copper ppm 0.05 max
Total hardness ppm as CaCO 3 0.3max

• Connections to the two refrigeration circuits must be provided:
- DN125 PN16 DIN2501 flanges at the inlet and outlet of the High Temperature circuit
- DN 65 PN16 DIN2501 flanges at the inlet and outlet of the Low Temperature circuit
• It is necessary that the primary circuits of the cooling systems be closed and independent for each
engine. Likewise, it is necessary to install expansion tanks capable of absorbing the expansion of
water in the face of temperature changes at different load regimes and capable of keeping the
circuits pressurized at a minimum static pressure. The minimum recommended volume for such
expansion tanks (open) is as follows:
Circuit Minimum volume in %
Aftercooler jacket
water 16 8
• Automatic vents must be available at the highest point of the installation, always avoiding the
presence of siphons in its design.
• Refrigeration circuits must incorporate isolation valves at inlets and outlets to facilitate
maintenance tasks.
• All flexible connections must allow electrical continuity between pipes, so copper braids must be
installed joining both sides of them.
• In the engine water inlet intakes of both circuits, conical "strainers" or dirt sifters must be installed
to eliminate dirt during the first engine starts. These strainers must be constructed in such a way
that they are easy to install (remove and/or put on) with a hole diameter of 0.4 mm so that they do
not create a very high restriction that could cause cavitation of the pumps.
• All pipes in the primary refrigeration circuits must undergo an initial "flushing" in order to
guarantee the absence of dirt in the circuits prior to filling them.
• In the event that pressure tests are carried out on the cooling circuits to detect leaks, the motors
must be completely isolated so as not to subject their components to excessive pressures that
could damage them.
• Every cooling system for motor generators used in cogeneration with thermal use must have an
auxiliary cooling system to eliminate heat that is not used in the process. Its control will be
carried out automatically by the client's control system.
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• In order to avoid heat losses and at the same time ensure personal protection, the pipes of the high
and low temperature circuits must be adequately heat-insulated.
• The thermostatic valve of the low temperature circuit (loose supply) must be installed at the motor
outlet, connecting its by-pass to the pump inlet (not included in the supply).
• It is advisable that the design of the cooling system of the primary circuit of the aftercooler
contemplates the connection of the aftercooler pump drive to the inlet and not to the outlet.
7 LUBRICATION SYSTEM
Includes the following items:
7.1 Oil pump

Of the gear type, with three pinions, moved by the motor. It has a relief valve to maintain constant
pressure at the pump outlet.
7.2 Oil filters

Two units composed of three paper elements each and service on the right side. It has an oil by-pass
valve to avoid excessive pressure losses when the filter is dirty.
7.3 oil cooler

It is part of the high temperature refrigeration circuit. It has a by valve pass that acts in case of
excessive pressure loss in the cooler.
The thermostatic valve at the oil pump outlet regulates the flow to the oil cooler. This thermostatic
valve maintains the oil temperature at 93ºC, which prevents supercooling of the oil.
7.4 Wet sump

It has a drain valve with 2" NPTF internal thread. It has two safety valves against explosion, which
open in case of overpressure (>0.07 bar).
7.5 Crankcase breathers

One on each side of the engine. Each of them consists of a nickel chip filter with cylindrical housing.
Outlet in elastic sleeve for connection to the customer's crankcase ventilation system.
7.6 Crankcase ventilation air filter

It allows air to enter the crankcase in order to promote the evacuation of corrosive vapors that form in
the crankcase.
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7.7 Automatic oil level control

Below the minimum setting limit, the crankcase filling valve is mechanically opened. Once the
maximum limit is reached, the valve closes. 1/2” GAS female thread connection for customer
connection.
7.8 Oil dipstick

Located on the right side of the engine with indication of the correct level when the engine is stopped or
when the engine is running.
7.9 Oil
The first filling of the crankcase is supplied with lubrication oil for natural gas engines (Mobil Pegasus
605 oil).
7.10 CEAD Program

With all engines of the G3500 family, Finanzauto SA offers a free one-year CEAD program
(Spectrophotometric Atomic Wear Control) which, with a commitment on the part of the client to send
an oil sample to our laboratories every 250 hours of operation , analyzes the level of engine wear in four
levels:
- Zero level
- Normal
- Special attention
- Immediate action
For this, special tubes are provided that must be sent

by mail to Finanzauto SA and a volumetric pump to
remove the sample from the crankcase.

7.11.1 Crankcase capacity
Total factory capacity (including filter capacity): 322 l
Oil refilling capacity with filter change: 310 l
7.11.2 Consumption
The specific oil consumption is 0.426 g/bkWh.
This consumption corresponds to the midpoint of the engine's life, at 100% power. In partial loads, said
specific consumption will increase, just as it did during the first hours of operation.
7.11.3 Specifications of the oil to use
Caterpillar considers it necessary that the oil to be used in its G3500 engines for biogas and landfill gas
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have the following characteristics:

• Specific oil for high compression ratio gas engines and extreme operating conditions.
• Low sulfated ash content (0.3-0.5% CB MIL-L-2104A Standard (Supp 1))
• Oils that have at least 6,000-7,000 h field results are recommended in lean burn gas engines with
powers similar to that of the G3500 or higher. Field results should include: oil consumption, oil
wear, and valve recession.
Caterpillar does not recommend specific brands of oil. Lubricant companies have control over their
products and must guarantee their quality and suitability for the engine.
7.12 Oil characteristics

Finanzauto SA supplies the first filling with Mobil Pegasus 605 oil for biogas and landfill gas engines
whose characteristics are:
OIL CHARACTERISTICS
SAE Grade 40
Viscosity at 40ºC cSt 130
Viscosity at 100ºC cSt 14
Pour point ºC max -12
Flashpoint ºC min 250
Viscosity index 96
Sulphated ash % weight 0,48
TBN mg KOH/g 6,0
- Connections to the different circuits of the lubrication system must be provided:
- Drain valve with 2" NPTF thread
- 1/2" female GAS thread to automatic crankcase level control
- 60.3 mm diameter elastic sleeves on the crankcase vents, for connection to pipes using clamps.
- The daily oil tank must be located at a maximum height of 3.6 meters above the crankcase level, and
it should be located inside the engine room.
8 FUEL SYSTEM
It is made up of the following elements:
8.1 Gas ramp.

Loose supply of the DN100 PN16 gas rail including support, for mounting by the customer as close as
possible to the engine gas inlet. Made of:
• Inlet and outlet flanges DN100 PN16 DIN2633
• Manually operated ball valve
• Basket type filter with 1 µ m filter mesh, with built-in purge valve (3/4"). The connection of said
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purge with the vent system is excluded from this supply.

• Pressure gauges with push-button valve. 0-600 mbar
• Double solenoid valve with slow opening and quick closing. 24Vdc.
• Sealing control valve. 24Vdc.
• Maximum and minimum pressure switches.
The approximate length of the gas train is 1,100 mm.
8.2 Flexible connection
Made of corrugated steel with 150 mm long internal telescopic sleeves, finished with a DN100 PN16
DIN 2502 flange for customer connection, located at the engine gas inlet.
8.3 Venturi type carburetor

Two units, one on each side of the engine, arranged after the air filters, before the turbocharger. They
are special carburetors for low PCI gas.
8.4 Butterfly valve
Located on the intake elbow, after the aftercooler. It automatically regulates the intake flow depending
on the load and engine rotation speed through the action of the EGS-01 regulator actuator.
8.5 TecJet fuel control system
The G3516 wet sump engine incorporates an electronic fuel control system that ensures adequate gas
flow under any circumstance. As part of this control system, there is a TecJet 110 regulating valve
located after the flexible gas inlet connection to the engine.
Working together with the EGS-01 engine control system, the TecJet system receives the desired gas
flow signal sent by the control system based on engine speed and load data.
The microprocessor located in the TecJet 110 will modify the position of the valve to allow the desired
flow to pass through. The position of the valve will also depend on the following variables: pressure,
temperature and density of the gas, and pressure loss in the valve.
In the event of variations in fuel demand, the TecJet is able to respond quickly, which results in optimal
engine performance.

• PCI fuel consumption: 2433 kW + 5%
• Pressure limits of the supplied gas (at the entrance of the ramp):
- Minimum pressure: 150 mbar
- Maximum pressure: 300 mbar
- Maximum supply pressure fluctuation: ± 17 mbar
The gas to be used must meet the following requirements:

- It must be dry, that is, it must not contain heavy liquid hydrocarbons (butane, propane)
- Minimum number of methane required: 130.
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Fuel usage guide:
Tariff factor / Timing vs. Methane Number

110 120 130+
0 0 1.0 / 20
- Minimum allowable methane content: 46%

To obtain the power indicated in this standard, a maximum methane content of 70% is required. For
higher percentages, there will be a power setting (see section 14: protections).
- Heating value: 17.7-23.6 MJ/Nm 3
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The following table indicates the allowable values in the gas composition, as well as the
contaminants and fuel conditions:
Grades
CH 4 % 40-70
CO 2 + N 2 % 45
H2 % 1
Sulfur compounds such as H 2 S 1,2 mgH 2 S/MJ 14
Halogen compounds such as Cl 1,3 MgCl/MJ 2,7
Ammonia MgNH 3 /MJ 1,4
Oil mg/MJ 0,14
Particles 1,4 mg/MJ 0,08
Silicon 1,4 mg Yes/MJ 0,14
Maximum temperature (ºC) 60
Minimum temperature (ºC) 10
Maximum relative humidity 5 (%) 80
(at the minimum gas operating temperature)
For the technical data included in this standard to be valid, it is necessary that the gas meets the
requirements indicated in this section. Values different from those shown must be studied by
Finanzauto, SA to calculate the engine performance and the feasibility of operation in different
conditions.
Grades:
1) The indicated limits include contaminants that can be ingested through the air.
2) Sulfur compounds are all those that contain sulfur. The total level of sulfur compounds should
include all sulfur and expressed as H 2 S.
3) Halide compounds are all those that contain chlorine, fluorine, iodine or bromine. The total level
of halide compounds must include all of the halides mentioned, expressed as chlorine.
4) The total particle content includes inorganic silicon.
The silicon limit includes the total silicon content, both organic (siloxanes, etc.) and inorganic.
5) Saturated fuel is acceptable, but water condensation in the fuel lines or engine is not acceptable.
At low temperatures heavy hydrocarbons can condense and enter the engine. The presence of
liquids in the gas is not allowed. If liquids are present, the customer must remove them by
increasing the gas temperature or using a coalescing filter. The engine can be seriously damaged
if liquids enter the engine.

• Connections must be provided to:
- DN100 PN16 DIN2502 motor inlet flange
- DN100 PN16 DIN2633 inlet and outlet flanges of the gas train
- 3/4" male GAS thread for the gas rail purge. The customer must take the duct for this
purge outside.
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• The section of pipe between the gas train and the engine is supplied by the customer. This pipe
must be adequately supported.
• The gas train should be installed as close as possible to the engine inlet
• All fuel circuit pipes must be cleaned with Nitrogen in order to guarantee the absence of dirt in
the circuit prior to filling.
• For the correct operation of the group, the client must supply a system for evaluating the
percentage of CH 4 in the gas with 4-20 mA output depending on said percentage. This analyzer
must have a self-calibration function, which checks the analyzer at least once a day. If the
analyzer oscillates, it should be checked more times a day. During analyzer calibration, the
output signal must be frozen. Finanzauto supplies this equipment optionally (see optional
section).
9 STARTING SYSTEM
Includes:
9.1 Starting motor

A 24 Vdc electric starter motor. When the starting maneuver is activated, the engine engages the
steering wheel and delivers the necessary speed to it to trigger the ignition. When the crankshaft
begins to rotate faster than the pinion, the engine disengages and stops.
9.2 Batteries
A set of two dry type batteries of 12 V each is supplied. The set includes 1880 mm long connection
cables, as well as a 1045 mm long and 270 mm wide bracket to place two batteries in each bracket.
9.3.1 Batteries
• Maximum peak starting current: 1300 A
• Maximum load capacity: 190 Ah
• Starting temperature range: > 20ºC
For the proper functioning and maximum duration of the equipment used to start the engine, it is
recommended to place the battery set in accordance with the following requirements:
• As close as possible to the starter motors.
• Accessible for easy visual inspection and maintenance.
• Protected from strong vibrations, sparks and against falling metal objects
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10 IGNITION SYSTEM
Because it is a lean mixture engine, the ignition system must provide higher voltages than normal as
well as long spark duration, both aspects necessary to achieve perfect ignition of the mixture.
The Electronic Ignition System (EIS) has been designed with this purpose, to achieve greater
reliability and duration of the ignition source. Its four main components are:
10.1 Control Module (EISM)
Its main functions are:
• Control of engine operation based on the information received from sensors.
• Ignition advance control and protection against detonation, delaying the advance.
• Voltage supply to transformers
Modifiable parameters can be predetermined through the software.
10.2 Sensors
The EIS consists of the following sensors to supply information to the control module.
• Sensor for detecting the degree of ignition advance: located on a special flywheel on the
camshaft.
• Two piezoelectric knock sensors located on both sides of the engine that transform the vibrations
or mechanical noises of knocking into electrical impulses.
• Intake pressure sensor: located in the intake manifold, through the measured pressure it
determines the degree of engine load.
10.3 Transformers
Each cylinder has an ignition transformer, located under the rocker covers. They have high
performance as a result of the minimal capacitive losses with which they work. Internally they have
an electrical noise filter that can generate the arc jump in the spark plug.
10.4 Plugs
Type J, resistive, with low radio interference. The electrode is made of precious metal.
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10.5 Cabling
It is basically divided into two parts:
• External wiring: connects the EIS control module with the sensors, batteries...
• Internal wiring: connects the control module with the primary circuits of the transformers.
11 ALTERNATOR
It is a three-phase synchronous alternator with accessible neutral, auxiliary excitation using a

permanent magnet, brushless main excitation winding and direct connection through rotating diodes
between its armature and the main rotor winding.
Characteristics :
• Insulation: class H with tropicalization and anti-abrasion (105ºC continuously).
• Maximum ambient temperature: 40ºC (30ºC in normal operation).
• Altitude: < 1000 m.
• Mechanical protection: IP22.
• Bearings: 1 self-lubricated rear with self-piloted alignment.
• Power terminal box: IP44 protection degree, located on the side, cable entry on the left side
seen from the coupling.
• Windings: made up of six cables connected in a star.
• Excitation: Permanent magnet.
Accessories :
• Digital voltage regulator (CDVR) with the following features:
* Programmable double-stage V/Hz regulation that favors the recovery of the group when
applying large blocks of load.
* Monitoring of rotating diodes.
* Local and remote control of voltage level and power factor.
* Alternator de-excitation.
* External signaling of grouped alarm and stop conditions.
* Communication software between CDVR and external hardware through RS485
communication port.
• 6 Pt-100 type winding temperature sensors (2 per winding).
• 2 anti-condensation heaters. 1.2 kW, 115-230 VAC single phase (total).
Intrinsic protections :
They are integrated into the voltage regulator itself with power factor control CDVR:
• Protection against loss of excitation, reverse power, maximum and minimum voltage
(adjustable).
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11.1 Technical
specification
General data at cos ϕ = 0.8:

Caterpillar SR4B Alternator
Power (kVA) 962,5
Power (kW) 770
Voltage (kV) 0,4
Speed (RPM) 1.500
Frequency (Hz) 50
Rated current (A) 1.389,24
Excitement PMG
Temperature increase (ºC) 105

Max. Ambient temperature
40
(ºC)
∆ U/U at 100% load (%) 5
No. poles 4
Protection IP22
Short circuit ratio 0,4757
Vibrations Watch TVA
Refrigeration Air
Construction type B3
Weight (kg) 3.401
Performances:
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% Burden 0.8 pf 0.9pf 1.0 pf
100 96,2 96,7 97,1
75 96,1 96,5 96,8
50 95,6 95,8 96,2
25 93,1 93,3 93,7
Reactances and time constants at cos ϕ =1:

Reactances (unitx100) Quadratic Direct
Subtransient - X"(s) 12 9,84
Transient - X'(s) - 14,23
Synchronous - X(u) 100,19 201,88
Negative sequence - X 2 (s) 10,92
Zero sequence - X 0 2,85
time constants Sec.
T”d 0 0,0117
T”q 0 0,0124
T”d 0,0015
T”q 0
T'd 0 4,1120
T'd 0,2899
Ta 0,0480
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• The exit of the power cables towards the medium voltage cells must not have any fixed point to the
engine-alternator-base structure to avoid the transmission of vibrations that could damage the
protective insulation of the cables.
• The metal closing cover of the power cable outlet can be removed or machined to connect the
power cables. If it is decided to mechanize, this piece must be cut and formed into two bodies to
avoid the effects of the electromagnetic fields created.
12 SPEED AND POWER CONTROL SYSTEM
This system is made up of a set of elements (Tecject, EGS and actuator) interconnected with each
other; which share the information sampled, processed and/or generated by them so that, through their
corresponding control algorithms, the pertinent actions are triggered on the fuel regulating valves
(Tecjet) and the position of the throttle actuator.
The master device of the system is the EGS-01 gas engine control board which controls the air/fuel
ratio for any engine speed and load conditions.
This control board is based on a microprocessor that is easily programmable through a PC to optimize
its operation under different operating conditions of the main parameters that affect motor regulation.
The EGS calculates the mass flow of fuel and transmits it to the Tecjet to regulate the amount of fuel
needed at each moment since it is an intelligent fuel measurement drive. In this way, the Tecject
receives an indicator signal of the required gas flow and density so that, through its control algorithms,
it informs the EGS of the temperature and pressure of the gas, differential pressure in the Tecject and
the position of the regulating valve. of the same.
Beyond what was previously described, the system is capable of maintaining optimal emission levels
for long periods of time.
Among the main advantages offered by the EGS-01 speed control system, the following can be
highlighted:
• Fuel metering and speed/load control of the gas engine.
• Improves the stability, performance and efficiency of the gas engine.
• Its combination with the Tecjet closed-loop gas quality system guarantees low levels of emissions
without the need for the use of oxygen sensors.
• Adaptive stoichiometric control.
• Remote communication capability through RS-232 port and programming with PC software.
• It facilitates the start-up phase and enhances the engine's diagnostic and monitoring capacity.
• Allows reliable operation of the mains-coupled motor.
• Flexibility of operating modes depending on your selection (open loop, closed loop, mono or
stereo operation and any combination of them).
• Temperature, overspeed and overload protection
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13 INSTRUMENTATION
13.1 Instruments panel
It is located on the right side of the engine. It has the following indicators:
- Oil temperature and pressure
- Jacket water temperature and pressure
- Oil filter differential pressure
- Temperature and pressure of the mixture in the intake manifold
- hourometer
- Digital and individual exhaust pyrometer for the 16 cylinders and output of the 2 turbos
- Independently powered digital tachometer
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14 PROTECTION SYSTEM
14.1 Engine protection system

Its main task is to protect the engine against unfavorable operating conditions, as well as to report its
status to the main control panel. Requires 24 Vdc power provided by the starting batteries.
The attached table summarizes the standard alarms and stops of the protection system.
ORIGIN GUY INSTRUMENT LIMIT

Overspeed Stop CAT Tachometer Relay 1770RPM
High jacket water temperature Stop Thermostat 120ºC
Jacket water temperature See Note 1 PT-100 98ºC
Low oil pressure Stop Pressure switch 2 bar
Air inlet temperature See Note 2 PT-100 See Note 2
High intake manifold temperature See Note 2 PT-100 See Note 2
Low gas pressure Stop Pressure switch 150 mbar
High gas pressure Stop Pressure switch 320 mbar
Detonation Alarm CAT Sensors and Control Detonation

Advance control severe
Stop and continued
Low oil level Alarm CAT automatic contact 120mm
(on
background)
Low jacket water temperature Alarm Resistance thermostat 21ºC
(with engine stopped) heating CAT
Low jacket water pressure See Note 1 Pressure switch 1.5 bar
Jacket water detection Stop CAT Detector (4P-9190) 0 Vdc
High oil temperature Stop Thermostat 102ºC
Methane percentage Detaring/Stop 4-20 mA signal (client) See Note 3

Note 1:
The motor protection system includes a stop protection if the minimum water pressure condition of 1.5
bar at the pump suction is not met, when the temperature exceeds 98ºC. The purpose of this protection
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is to prevent vaporization of the coolant and cavitation in the pump impeller.

Note 2:
The engine protection system includes a control system based on the temperature rating table provided
on page 10 for the altitude corresponding to the plant. Depending on the ambient temperature (input to
filters) the control loop will provide the AVAILABLE POWER (PD) in the plant at all times.
Likewise, a system is included to control the electric power of the group depending on the temperature
in the engine intake manifold. This control loop will be based on a hysteresis cycle (two different
loading ramps depending on whether the temperature increases or decreases) whose characteristics are
the following.
ο Coordinates of the points that define the control loop

1. Temperature increase :
Tª < 62 ºC..........................................................100 % of PowerAvailable

Tª = 71 ºC........................................................... 95 % of PowerAvailable
Tª > 71 ºC..............................................................0 % of PowerAvailable
If the intake manifold temperature rises above 71ºC, the group switch will trip, the engine will idle for
5 minutes in the cooling cycle and then stop.
2. Decrease in temperature
71 ªC > Tª > 64 ºC............................................95% Available Power

Tª < 55 ºC.........................................................100% Available Power
The explanatory graph of the proposed hysteresis cycle is attached:
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Note 3:
The protection system includes a group power control system based on the percentage of methane in
the fuel gas, provided by a CH 4 evaluation system with 4-20 mA output. This analyzer is not included
in the standard supply, and is supplied as an option (see section 20.3.1.).
- CH 4 <30%………………………….. engine stop

≤ ≤
- 30% CH 4 46%………………… Motor retardation according to attached curve (*)
- 46%< CH 4 < 70%…………………100% Available Power
- 70<% CH 4 <100%……………….. 94% Available Power (*) Operation in the 30-46%
range is not recommended for continuous periods of time and must be studied for each particular case.
The graph of the proposed control system is attached:
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• The protection box is supplied on a support on the engine bed, for placement on the ground.
14.2 Alternator protection system
The protections provided by the CDVR are the following:
• Maximum overvoltage.
• Low voltage.
• Loss of signal in the CDVR.
• Fault monitoring in rotating diodes.
• Overexcitement.
• Loss of excitement.
• Reverse power.
15 BASIC CHART OF COGENERATION
This is a control, protection, monitoring and network coupling panel for a motor-generator group.
15.1 Metal carpentry

The control panel will consist of two panels corresponding to group control and common control, and
whose main characteristics are the following:
• Overall dimensions: height 2100 mm, width 1600 mm. and depth 800 mm.
• Registrable for its previous part.
• Constructed of 1.5 mm steel sheet. of thickness.
• 2mm front doors. thick equipped with neoprene gaskets and latch closures with key on the left
side.
• Protection treatment against oxidation by degreasing and priming.
• Baked paint in RAL 7032 color.
• Lifting eyebolts.
• Access to terminals from the bottom
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• Assembly of control, command and signaling elements on its doors.
• Protection degree IP-44.
• Direct support without anchors.
• General ground connection.
• Identification of external elements with gravoply adhesive labels and numbered stickers for the
equipment inside.
• Cables and connection strips perfectly channeled and numbered.
15.2 Equipment
15.2.1 Control PLC
To control the generating set and the network, a PLC (programmable controller) will be installed,
made up of the following elements:
• 1 CPU Central Unit, with 256K of RAM memory and two communication ports (1 RS232 and 1
I/O Bus).
• 4 I/O Bus communications adapters.
• 2 Modules with 32 digital inputs at 24 Vdc.
• 1 Module with 32 digital outputs at 24 Vdc.
• 1 Module with 4 inputs and 2 analog voltage/current outputs.
• 5 screw connection terminals.
• 4 I/O Bus cables of 11 cm.
The PLC will be in charge of processing the different operating parameters and appearance of alarms,
which can be viewed and controlled through a graphical operator terminal with a touch screen,
communicated through the Modbus serial port of the PLC.
15.2.1.1 Group control

• Control of power to be generated.
• Power rating as a function of intake manifold temperature.
• Power rating as a function of temperature in the input filter.
• Power rating based on the percentage of methane in the fuel gas.
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• Operation timings.
• Remote start in cogeneration by closing a potential-free contact.
15.2.1.2 Alarm control

The PLC will control the alarms produced in such a way that they cause an acoustic and light signal
(intermittent flashing) on the screen, and the stops also cause a stop of the group as well as additional
actions depending on the type of alarm produced.
15.2.2 Graphic Operator Terminal
The graphical operator terminal will be equipped with a 32-bit RISC CPU and a 9” electroluminescent
LCD touch screen.
This terminal is located in the common control panel, and its main function is to communicate with
the PLC to display states and alarms, as well as to adjust operating parameters.
It integrates a series of differentiated menus, which can be accessed by pressing the corresponding
icons on the touch screen:
• Main menu for access to the rest of the menus, with a single-line diagram of the plant that reflects
the states of switches and disconnectors and indication of generator power.
• General alarm menu, with access to alarm group submenus.
• Start menu, with group start and stop orders, and display of the group start conditions.
• Group settings menu, with maximum power to generate, load up and down ramp time, etc.
15.2.3 Protections
15.2.3.1 Engine
The following signals are included for alarms and engine stops, which will be transmitted by the
group's protection panel, which is located next to the engine:
• Low oil level alarm.
• Alarm for low jacket water temperature.
• Shutdown due to low jacket water level.
• Stop due to overspeed and/or emergency stop.
• Shutdown due to low oil pressure.
• Shutdown due to high jacket water temperature.
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• Stop due to high oil temperature.
• Shutdown due to the ignition system.
• Stop due to tripping of supervision system protections.
• Shutdown due to low jacket water pressure if the water temperature exceeds a value.
From the engine gas train:
• Shutdown due to low gas pressure.
• Shutdown due to high gas pressure.
• Alarm for tightness control.
From the gas analyzer:
• Content signal in CH 4 for control loop of the generated power.
Detarages: (See section 15.2.1.1 Group control)
15.2.3.2 Generator
• Warning alarm in DVR generator voltage regulator.
• DVR generator voltage regulator trip alarm.
• Overload/short circuit (50/51): Protection relay with current adjustment

overcurrent and trip time in two stages (I> and I>>):
ADJUSTMENT
PARAMETER SYMBOL
MARGIN
Overcurrent trip current I> 0.5 – 2 x In
Overcurrent trip time tI> 0.1 – 2s
Rapid tripping current due to overcurrent I>> 1 – 15 x In
Fast overcurrent trip time tI>> 0 – 2.5s
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• Voltage out of limits (59/27): Protection relay with adjustment of maximum and minimum trip
voltage, trip time, and trip due to difference between maximum and minimum conductor voltage:
ADJUSTMENT
PARAMETER SYMBOL
MARGIN
Trip overvoltage U> 90 – 130% A
Preset trigger time t∆U 0 – 10s
Minimum trip voltage U< 70 – 110% A
Trip due to difference between the maximum and

DIFF 2 – 10% A
minimum voltage of the conductors
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• Frequency out of limits (81M/81m): Protection relay with adjustment of maximum and minimum
frequency and trip times:
ADJUSTMENT
PARAMETER SYMBOL
MARGIN
Trip overfrequency f> 100 – 108% fn
Overfrequency trip time t f> 0 – 10s
Minimum trigger frequency f< 92 – 100% fn
Tripping time due to minimum frequency t f< 0 – 10s
15.2.3.3 Tie rods

• Voltage out of limits (59/27): Protection relay with adjustment of maximum and minimum trip
voltage, trip time, and trip due to difference between maximum and minimum conductor voltage.
• Network microcut (78): Protection relay with vector jump adjustment and activation delay:
ADJUSTMENT
PARAMETER SYMBOL
MARGIN
Voltage Vector Jump ∆ϑ 1 – 31º
Activation delay tv 0 – 10s
15.2.4 Synchronizer
• WOODWARD synchronizer.
15.2.5 Extent
The following measuring equipment is included:
15.2.5.1 Generator
Multimeter/network analyzer, rail-mounted, with remote display on the front of the cabinet, which
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includes measurement of 32 group electrical parameters (voltages, currents, powers, frequency, power
factor, energies, etc.); It incorporates two 4..20 mA outputs for transmission to the PLC of the active
power and power factor of the group.
15.2.5.2 Synchronization
• Synchronization arm consisting of a synchronoscope.
15.2.5.3 Engine
• Intake manifold temperature (displayed on the operator terminal).
• Air temperature in the inlet filter.
• Percentage of methane in fuel gas.
15.2.6 Signaling
Within the section corresponding to signage, the following is included:
• Indication of status of auxiliary equipment.
• Group switch status.
• Engine condition.
15.2.7 Pushbuttons and selectors
The set of buttons and selectors includes the following:
• Emergency stop mushroom.
• Group starter lock key.
• Group operating mode selector (Automatic - Manual).
• Manual start and stop of the engine.
• Manual closing and opening of the generator switch.
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Manual operation can be carried out by pressing the engine start-stop and switch closing-opening
buttons.
15.2.7.1 Generator switch closure

• Signal sending instant: During the synchronization sequence and when a bus source is detected,
once voltage, frequency and phase have been equalized on both sides of the switch. Without
source in bars, instant.
• Signal type: Pulse until bar source detection, by potential-free contact.
15.2.7.2 Generator switch opening

• Signal sending instant: Whenever the group stops for any reason or one of the generator protection
relays is triggered.
• Signal type: Permanent, potential-free contact.
15.2.8 Converters
For the processing of analog signals from the control PLC, the following is incorporated:
• Load signal converter to “EGS-01” 4..20 mA / 0..5V.
• Intake manifold temperature converter PT100 / 4..20 mA.
• Air temperature converter in the input filter PT100/4..20 mA.
15.2.9 Auxiliaries
The group's auxiliary system incorporates the following elements:
15.2.9.1 General AC power

4-pole protection switch, 40A, with status contact for alarm signaling.
15.2.9.2 Battery charging system

• Battery charger and stabilized DC source, with the following characteristics: input voltage 3x400
Vac, output voltage adjustable between 24 and 27.5 Vdc and maximum output current 18A.
• Voltmeter and ammeter for measuring batteries.
• 1-pole automatic switch, 20A.
• 1-pole automatic switch, 16A.
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15.2.9.3 Engine heating system
• AC power protection switch 1 pole, 32A.
• Contactor control switches, 1 pole, 6A.
• 32 A contactor.
• Signaling pilot.
15.2.9.4 Generator heating system

• Power protection switch CA1 pole, 6A.
• 9A contactor.
15.2.9.5 Gas train system
• 24 Vdc power supply to the tightness control.
• Contactor for 24 Vdc power supply to the two main valves.
• Reception of the correct tightness control signal.
15.2.9.6 Power supply and panel lighting system

Each panel includes:
• AC power protection switch, 1 pole, 6A.
• Socket socket, 2 poles with side grounding, 16A.
• Apply with 60 W soffit tube.
• Ignition switch.
15.3 Observations
For the development of electrical diagrams and control panel design, the client must provide the
following signs and information:
• Electrical single-line diagram of the existing installation.
• Current transformer signal x/5 for generator protection, class 5P10.
• Intensity transformer signal x/5 for generator measurement, class 0.5.
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• Voltage transformer signal x/110: √ 3 for synchronization, class 0.5. Installed on coupling rods.
• Voltage transformer signal x/110: √ 3 for generator protection, class 3P.
• Voltage transformer signal x/110: √ 3 for generator measurement, class 0.5.
• Status signal of the network switch, and network voltage and ammeter protections.
• Status signal of the disconnectors or devices that may involve cogeneration operation of the group
(remote tripping, tripping of group switch protections, disconnectors, etc.).
All materials and specifications not reflected in the scope of this standard supply are excluded from
this standard supply, and specifically the following:
• Permits and legalizations
• Other voltage and intensity transformers necessary or requested by the client
• Additional network or generator protection elements, which may be needed or required by the
electricity company
• Protocols and communications between the PLC and the client's distributed control system, if any.
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16 VENTILATION
16.1 Room ventilation

Calculation of the necessary air flow :
- Thermal power radiated by the alternator: 23 kW
- Thermal power radiated by the motor: 89 kW
- Required air flow: 43,000 Nm 3 /h, for a thermal jump of 10 ºC
To this air flow we must add that required by the intake, 2,939 Nm 3 /h. Thus, the flow rate to be
provided by the room ventilation system must be 45,940 Nm 3 /h per motor.
1. The air inlet must be

located in the lower part of the
room and in such a way that,
first of all, the alternator is
cooled and then the engine,
placing the air outlets in a top
position, on the opposite side of
the room. □
2. In rooms with several motor

generators, the ventilation flow must follow
the direction of the motor axes and the flow
must be distributed equally for uniform
elimination of the heat generated by the motor
generators.
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16.2 Crankcase ventilation

• Crankcase vapor flow: 32 m 3 /h
• It must be ensured that the vacuum in the crankcase does not exceed –2.5 mbar

The design and installation of the crankcase ventilation system is customer supplied. Said installation
must meet the following requirements:
• The engine crankcase ventilation system includes an air filter to promote the elimination of
corrosive vapors present in the gases (H 2 S, HCl, HF, H 2 SO 4 ). To prevent the deterioration of
the lubricating oil due to crankcase gases, the customer must install a forced ventilation system,
consisting of at least the components indicated below (see figure):
- Fan: must provide a flow rate of 32 m 3 /h with adequate pressure to overcome the
restriction in the crankcase vent pipe. Finanzauto optionally supplies this fan (loose
supply). It is recommended to install a drip tray with condensate drain.
- Pipe between vent and collector: the initial section of pipe (approximately 0.5 m) must be
made of temperature-resistant material (gas temperature: 110ºC) and with a minimum
diameter of DN80. A butterfly valve will be installed to regulate the vacuum in the
crankcase.
- Collector: will be made of 152 mm diameter PVC pipe, with a positive slope (3-5%
inclination). At the furthest point from the fan, a butterfly valve must be installed to adjust
the manifold vacuum, as well as a drain valve.
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• The ventilation circuit outlet must be located outside the engine room.
• Separate ducts must be provided for each motor.
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17 MOUNTING SYSTEM
17.1 Common steel engine-alternator bench

Two steel rails, with a "U"-shaped profile, 330 mm high, and fixed by bolts to the motor-generator
assembly. It maintains the alignment between the engine and the alternator, supports bending and
torsion forces and allows thermal expansion of the parts due to the increase in temperature.
17.2 Anti-vibration pads

Six studs with spring and shock absorber. They are supplied loose, for distribution in six support
points for the seating of the engine on the customer's concrete bench. Anchoring to the concrete bench
is not necessary.
Materials:
- High resistance spring steel spring with anti-rust protection
- Aluminum locking washers.
- Multiple coupling plates in steel
These plugs allow the placement of the motor-generator on the ground floor of a building. If the
location is special (terrace, platform...) Finanzauto SA can provide other optional anchoring systems.

The motor-generator must rest on a concrete bench whose design must meet the following minimum
requirements:
• The minimum concrete mix will be 1:2:3 of cement, sand and inert material.
• The minimum dimensions will be:

- Length = total length of the motor-generator bed + 310 mm on both sides
- Width = total width of the motor-generator bed + 310 mm on both sides
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- Height = Weight (kg)/ [ concrete density (kg/m 3 ) x length (m) x width (m) ]
A plan is attached with dimensions of the bench, considering the average density of the concrete to
be 2,402.8 kg/m 3 .
• The bench must be reinforced with a network of 15 steel rounds placed horizontally with distances
between centers of 150 mm or 20 with distances between centers of 300 mm. The net will be
placed at a depth of 75 mm below the surface of the bench.
• It can be a semi-floating bench with 50 mm thick insulation on the side walls or a floating bench,
when its base is also covered with insulation. In both cases, the bench must rest on a platform of
200 to 250 mm of gravel or moist, compacted sand.
• It is not necessary to anchor the motor-generator supports with bolts.
• The maximum allowable difference in level at all support points of the concrete surface is 6 mm.
The surface on which the anti-vibration pads rest must be smooth.
• It is recommended that the concrete bench be at ground level and not elevated.
• In installations with two or more motors, the minimum recommended distance between motors
must be such that the distance between motor axles is 3.2 meters.
18 STEERING WHEEL ASSEMBLY
It is composed of:
18.1 flywheel
It is fixed to the rear end of the crankshaft by bolts. It fulfills a double function. On the one hand, it
regularizes the rotation movement of the crankshaft, giving it greater inertia and uniformity. On the
other hand, the pinions of the starter motors mesh in a crown mounted on its perimeter, from which it
receives the necessary force to start the movement.
18.2 Case
It is a steel casing that covers the perimeter of the assembly formed by the flywheel and the starter
ring, also supporting the two starter motors.
18.3 Vibration damper

It is a device connected to the front face of the crankshaft, inside which there is a viscous liquid that
dampens the torsional vibrations generated by the efforts of the connecting rods on the crankshaft.

• Flywheel: SAE 00 rotation, nominal shaft fixing size: SAE21
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• Flywheel housing: SAE 00
19 ACCESSORIES
19.1 Lifting eyes

The lifting eyebolts are for lifting the engine only and exclusively. Under no circumstances should
they be used to lift the engine-alternator group.
19.2 Identification signs

All equipment that requires it has different stickers with instructions in Spanish.
19.3 Plastic protection

The entire group and incorporated elements are delivered with a plastic protection to protect them
from humidity and corrosion.
19.4 Documentation
A set of installation and maintenance manuals for the motor-generator in Spanish, as well as guides
and disassembly manuals in English, are supplied with each group. Likewise, technical documentation
of the auxiliary equipment (crankcase emptying pumps, gas train, etc.) will be supplied.
20 OPTIONAL
The characteristics of those elements not included in the standard but that can be included in the
supply at the customer's request are described below.
20.1 Exhaust system

20.1.1 Silent
20.1.1.1 Description
Silencer with radial or axial inlet and axial outlet, with DN300 PN10 DIN2576 flanges for connection
to the customer's exhaust system.
The material is stainless steel and therefore resistant to high exhaust temperatures and possible
corrosion due to the condensation of acidic components present in the exhaust gases.
Supplied loose, along with flanges, counterflanges, gaskets and screws.
The assembly and insulation of the exhaust silencer will be the responsibility of the customer.
20.1.1.2 Technical specification
The technical characteristics are indicated below:

• 40 dB(A) attenuation due to reactive-absorbing operation
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• Residual exhaust sound pressure at 1.5 meters from the silencer:
63Hz 125Hz 250Hz 500Hz 1000Hz 2000Hz 4000Hz 8000Hz Filter A
Sound 69 dB 65dB 62 dB 59 dB 60dB 65dB 67 dB 69 dB 73dB(A)

pressure
• Pressure drop at 100% engine load: 13 mbar

• Approximate dimensions and weights:
- Weight: 300kg
- Maximum diameter: 808mm
- Total length: 3240 mm (axial entry), 3156 (radial entry)
20.2 Refrigeration system

20.2.1 Heating resistors
6 kW electrical resistance, single-phase 240 V. Its function is to preheat the engine cooling water, thus
facilitating engine starting and charging.
A thermostat indicates when the cooling water reaches a temperature of 60ºC. Likewise, it has a
thermostat to alarm for low water temperature at 21ºC to detect any anomaly in the heating.
20.3 Fuel system
20.3.1 CH 4 Analyzer
Optionally, Finanzauto supplies a gas analyzer to measure CH 4 by the absorption effect of infrared
and oxygen, Siemens brand, Ultramat 23 model, with indication panel and local management
included. It has a self-calibration system with air every 6 hours, which guarantees the measurement
precision of the analyzer.
Power: 230 Vac 50Hz.
It has an internal gas suction pump and a 6 mm outer diameter tube, for connection to the gas inlet
pipe to the engine. This connection is customer supply.
The scope of supply also includes IP54 cabinet with transparent door, dimensions 500x600x460 mm
(HxWxD). Inside said cabinet the analyzer will be located along with the following accessory
elements:
• Moisture detection equipment
The gas to the analyzer must be dry. To protect the equipment against high humidity levels
(>80%), there is a universal filter with a fiberglass filter element and a humidity sensor that
gives an alarm signal and stops the gas suction pump in case of humidity detection.
• Calibration equipment
A 3-way manual valve is included, for calibration using a CH 4 bottle. The bottle and pressure
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reducer for calibration are optionally supplied separately from the analyzer (supply and rental
for one year).
20.4 Lubrication system

20.4.1 Crankcase filling/draining pump
One pump per motor is supplied, loose, for placement in the customer's installation.
These are positive displacement and self-priming pumps, with a mechanical closure system and safety
valve. The construction materials are: cast iron pump body, nitrided steel central spindle and nitrated
pearlitic cast iron side spindles.
Additional technical data of the pumps is indicated in the following table:
Capacity (l/min) Power 18.5 (see note) 0.76 Three-

(CV) Power Connections phase 400 V 1450 rpm GAS
thread 1" female
Note: this capacity corresponds to an oil viscosity of 380 cSt.
If this option is selected, the control panel will include the following:
• Circuit breaker-magnetic thermal motor for AC power 3 poles, regulation 1-1.6A.
• 9A contactor.
• Contactor control switch, 1 pole, 6A.
A box with a start/stop selector is delivered for installation at the foot of the pump (this installation is
not included).
20.4.2 Crankcase exhaust fan
Optionally, Finanzauto supplies the fan for the forced crankcase gas ventilation system. Its
characteristics are the following:
Medium pressure centrifugal fan (anticorrosive) with polypropylene casing and turbine, asynchronous
motor with squirrel cage rotor, three-phase motor 230/400 V 50 Hz, class F insulation and IP-55
protection.
- Flow rate: 32 m 3 /h
- Static pressure: 100 mm.ca
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20.5 Speed and power control system

20.5.1 Load sharing module
It makes it possible to distribute loads between several generating units, and controls the load of the
motor-generator set coupled to the grid. Supplied loose.
20.6 Control Box

The following equipment is offered as an option, which will be chosen by the client:
• Control of import and/or export of energy.
• Control of power factor in grid interconnection.
• Network measurement.
• Group start/stop time control.
• Complete timing arm.
• Communications port for the client's distributed control system.
• Monitoring of group parameters.
• Measurement and protection of the temperature of the generator windings.
• Measurement and protection of the temperature of the generator bearings.
Measurement and protection of the temperature of the engine cylinders and exhausts.
• Module with 4 digital alarm/stop inputs.
• Protection against homopolar current of the generator.
• Control batteries.
• Measurement and protection of the temperature of the windings and bearings of the generators.
20.7 Accessories
20.7.1 Toolbox
Optionally, each group includes a box of tools necessary for the assembly and disassembly of the basic
engine parts.
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20.8 Transport
Optionally, the delivery on site on a truck is included in the supply.
21 REGULATIONS, QUALITY AND SAFETY
21.1 Thermal and acoustic insulation

21.1.1 Thermal isolation:
The customer supplies the heat insulation of all the elements of the exhaust system, as well as the
pipes of the high and low temperature circuit of the engine.
21.1.2 Acoustic isolation

To achieve adequate acoustic insulation, the client must provide for the installation of acoustic
insulation in the air intake and extraction as well as in the walls, doors and windows of the machine
room. In section 1.3. Mechanical noise and exhaust sound pressure data are indicated.
21.2 Emissions and discharges
To facilitate oil changes, it is recommended that the customer have a tank capable of holding the dirty
oil until it is collected by an authorized company.
See section 5.5.2 for exhaust gas emissions level.
21.3 Electricity
The installation and electrical components supplied will comply with the High and Low Voltage
Regulations.
21.4 Paint
The motor-generator is supplied painted in Caterpillar yellow.
21.5 Protections and security
All moving parts will be perfectly protected to avoid possible accidents, complying with work safety
regulations at all times.
21.6 Regulations and quality
The equipment is supplied in accordance with current standards and regulations.
All G3500 units have a motor-generator incorporation certificate in accordance with European
directive 98/37/EC, article 4.2, appendix II, section B.
All materials, accessories and equipment will be new and from top brands on the market. All
Caterpillar elements have the guarantee of their origin: manufacturing according to ISO-9001 quality
certificate.
21.7 Factory tests
All G3500 engines are bench tested.
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22 START UP
Both Finanzauto and Caterpillar consider it a priority to carry out a good start-up of all their
equipment, which is why we have perfectly qualified technicians for this task.
With each unit of gas that Finanzauto supplies, assistance is provided for the start-up of a technician
specializing in gas motor generators who will carry out the necessary checks in the installation of all
those supplies from Finanzauto, especially those related to auxiliary equipment supplied by others.
The Finanzauto specialist is an expert in mechanics, electricity, fuels, etc.

For the start-up, Finanzauto has planned the assistance of the technical team for a total period of three
days in one or two trips. The use of said period may be determined by the client, or engineering
designated by it, in the manner considered most appropriate for optimizing the start-up of the
equipment.
In the event that due to any defect in the Caterpillar equipment or any other Finanzauto supply, the
assistance of extraordinary personnel or for a period of time longer than that provided for in the
previous paragraph was necessary, Finanzauto would use the necessary human and technical means in
the time necessary to achieve delivery in accordance with the conditions established in this
specification.
If, for reasons beyond the control of Caterpillar equipment or other Finanzauto supplies, it is necessary
to extend the start-up period, the client must accept the cost of the stay and travel of our technicians to
the site during the requested period of time.
The tests will not begin until gas is available and the corresponding permit from the company for the
coupling is available and once the installation of all equipment other than Finanzauto is complete.
23 CATERPILLAR WARRANTY: GENERATING SET
(Effective with sales made on or after January 1, 1997).
Caterpillar warrants that the following products sold for use as motor generators are free from defects
in material and workmanship.
Applies to new engines, MCE (Major Component Exchange) Program engines, and Rebuilt engines.
This warranty is subject to the following terms and conditions:
23.1 Warranty period

The warranty period indicated below will apply according to whichever occurs first after delivery to
the first owner.
• New motors used in motor generators and electrical energy generating equipment: 12 months (24
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months for auxiliary generators).
23.2 Caterpillar Obligations

If a defect in material or workmanship is discovered during the warranty period, Caterpillar, during
normal business hours and at a Caterpillar agent location or another location authorized by Caterpillar:
• You will supply (at Caterpillar's option) such new, MCE, rebuilt or repaired parts under
Caterpillar authorization or assembled components as are necessary to correct this defect.
Note: Parts replaced under this warranty become the property of Caterpillar.
• You will bear the reasonable and customary labor necessary to correct the defect, including the
labor necessary to disconnect and reconnect the unit to the equipment to which it is mounted, as
well as its anchoring and fastening elements, if necessary.
• You will bear the justified travel expenses of the authorized mechanics, including meals and
accommodation and mileage when Caterpillar decides to have the repair carried out on site.
• It will replace lubricating oil, filters, antifreeze and other maintenance materials that this defect
has left unusable.
23.3 Client Obligations

The client's obligations are:
• Labor not explicitly included in the "Obligations of Caterpillar", which includes labor not strictly
necessary to disconnect and reconnect the unit to the equipment to which it is mounted, as well as
its anchoring elements and subjection.
• Expenses generated by the transportation of the unit or the equipment in which it is installed.
• Travel expenses not included among "Caterpillar Obligations".
• Shipping costs for parts other than the normal and usual ones.
• Local taxes, when appropriate.
• Expenses generated by the investigation of complaints, unless the problem was the result of a
Caterpillar material or manufacturing defect.
• Notify in time of a breakdown covered by warranty and quickly make the unit available to the
people in charge of repairing it.
23.4 Restrictions
Caterpillar is not responsible for breakdowns caused by:
• An installation or application that Caterpillar deems inappropriate.
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• Accessories, implements or parts not sold by Caterpillar.
• Misuse, neglect and/or incorrect repair.
• Unjustifiable delay by the customer in making the unit available to the people in charge of
repairing it, once informed of a possible problem in that unit.
NEITHER THIS WARRANTY NOR ANY OTHER CATERPILLAR WARRANTY, EXPRESS OR

IMPLIED, IS INTENDED TO APPLY TO PRODUCTS SOLD BY CATERPILLAR, BUT FOR
WHICH THE MANUFACTURER ALREADY GRANTS A WARRANTY FOR THEM TO THEIR
OWNER.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING ANY WARRANTY REGARDING THE FITNESS OF THE UNIT FOR
THE MARKET OR ITS FITNESS FOR ITS INTENDED USES. THE REMEDIES UNDER THIS
WARRANTY ARE LIMITED TO THE SUPPLY OF MATERIALS AND LABOR AS EXPRESSED
HEREIN. CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
The name "Caterpillar", as used in this document, refers to Caterpillar Inc. or one of its
subsidiaries, with the exception of Caterpillar of Australia Ltd., whichever was the last to sell the
product in question.
The material that comes with the factory built-in engine is subject to the same as Caterpillar
material.
Material that FINANZAUTO, SA incorporates into the unit.
23.5 Warranty term

The one indicated by the manufacturer and is processed through FINANZAUTO, SA.
Processing method:
a) The client complains to the base and it resolves it either through its media or directly to the
manufacturer.
b) The customer makes a claim directly to the local distributor of the product, indicating
which unit it belongs to.
24 ANNEXES
The following plans are attached below:
FG750LD-01 Right Side View
FG750LD-02 Front View
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FG750LD-03 Left Side View
FG750LD-04 Rear view
FG750LD-05 Plan view
FG750LD-06 Bed footprint
FG750LD-07 Connections
FG750LD-08 Concrete bench
FG750LD-09 P&ID
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Caterpillar 3512 Engine Technical Data PDF

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(i Barloworld CAT

1 THE G3500 ENGINES............................................................................................................8

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5.5 Technical specification...............................................................................................20

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13.1 Instruments panel........................................................................................................39

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2) All pressures that appear in this document are relative

1 THE G3500 ENGINES

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the natural choice!

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2 TECHNICAL DATA OF THE MOTORGENERATOR

Alternator SR4B brushless, 962.5 kVA 400 V

Brake horsepower 803 bkW

Electrical power (cos ϕ = 1) 780 ekW

Setting 12 cylinders in V at 65º

Bore x Stroke 170x190mm

Displacement 51.8 liters

Compression ratio 12:1

Ignition sequence 1-12-9-4-5-8-11-2-3-10-7-6

Rotation CCW. SAE standard

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2.1 Powers, performances and emissions

ENGINE SPEED (RPM) 1500 11:1 FUEL Landfill Gas/Biogas

100 % 75% 50%

BRAKE HORSEPOWER bkW 803 602 402

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Engine Radiation: ±25%

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Height (including vibration dampers and exhaust expander): 2245 mm

Length (engine-alternator): 4565mm

Weight with liquids: 12000 kg

2.2.2.2 Group components

Steering wheel: 155kg

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2.3 Sound levels

1.0m 7.0m 15.0m

2.3.2 Sound pressure due to exhaust gases at 100% load

1.5m 7.0m 15.0m

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mechanism more rigid.

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4.2 Air filter

4.6 Installation guide

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It is made up of the following elements:

5.1 Exhaust manifolds

5.2 By-pass valve

5.3 Flexible connection

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5.5 Technical specification

% Burden 100% 75 % 50%

Exhaust gas mass (wet) (kg/h) 4272 3395 2701

5.5.2 gas emissions

Maximum deformations are not cumulative

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5.6 Installation Guide