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Caterpillar G3500 Engine

Name: Caterpillar G3500 Engine
Brand: Caterpillar

The Caterpillar G3500 is a naturally aspirated,turbocharged/aftercooled engine, producing up to 472 kW. It powers generator sets from Caterpillar, including the G3508 TA, G3512 TA, G3512E and G3516 NA.

Also known as: Caterpillar G3500

472 kW

Gross power

On this pageSpecs Generator sets Maintenance FAQ Torque & specs Fluids Procedures

Engine specifications

Aspiration	Naturally Aspirated,Turbocharged/Aftercooled
Gross power	472 kW

Generator sets powered by this engine

Caterpillar G3508 TACaterpillar G3512 TACaterpillar G3512ECaterpillar G3516 NACaterpillar G3516BCaterpillar G3516ECaterpillar G3520Caterpillar G3520B TA

How to read your Caterpillar engine serial & model number →

Maintenance schedule

Item	Spec	Part #	Interval
Air filter	Clean with soap and water solution if differential pressure exceeds 15.2 mm (0.6 inch) of water; replace if necessary	—
Fuel filter	one micron particle size with maximum 2 psi	—
Oil filter	Replace at every oil change, at 100 kPa (15 psi) differential pressure, or at 1500 operating hours, whichever occurs first	—	1500 hr
Battery		—
Belt		—
Coolant		—	24000 hr
Oil		—
Spark plug	Electrode gap: compression ratio >9:1 = 0.29 ± 0.03 mm (0.011 ± 0.001 inch); compression ratio ≤9:1 = 0.35 ± 0.03 mm (0.014 ± 0.001 inch). Install torque 68 ± 4 N·m (50 ± 3 lb ft)	—

Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.

Service specifications

Type	Item	Value	Unit	Condition
Gap	Spark Plug Electrode Gap - Compression Ratio 9:1 or Less	0.35 ± 0.03 mm	mm (0.014 ± 0.001 inch)	compression ratio <= 9:1
Gap	Spark Plug Electrode Gap - Compression Ratio Greater Than 9:1	0.29 ± 0.03 mm	mm (0.011 ± 0.001 inch)	compression ratio > 9:1
Other	Engine Oil Filter Service Life Limit	1500	operating hours	replace at every oil change, at 100 kPa differential pressure, or 1500 hours, whichever occurs first
Other	Rating condition (diesel 7 L and higher)	99 kPa (29.31 in Hg) dry barometer, 25°C (77°F)		SAE J1995 inlet air standard
Other	Rating condition (diesel up to 6.6 L)	100 kPa (29.5 in Hg) total barometric pressure, 1 kPa (.295 in Hg) vapor pressure, 25°C (77°F)		ISO/TR14396 inlet air standard
Other	Rating condition (gas)	100 kPa (29.61 in Hg) and 25°C (77°F)		SAE J1349 standard
Pressure	Air Inlet Filter Differential Pressure - Clean Threshold	15.2 mm	mm (0.6 inch) of water	clean filter when reached
Pressure	Engine Oil Filter Differential Pressure - Replace Threshold	100 kPa	kPa (15 psi)	replace filter when reached
Pressure	Explosion relief valve opening pressure	1.6 psi (11 kPa)	psi (kPa)	per valve
Pressure	Oil Pressure After Oil Filter Change (crank check before start)	70 kPa	kPa (10 psi)	crank engine with fuel supply closed until gauge reaches this value
Resistance	Spark Plug Resistance - 146-2588 Spark Plug	approximately 1000	ohms
Resistance	Spark Plug Resistance - 194-8518 Spark Plug	approximately 500	ohms
Torque	Air Inlet Filter Service Indicator	2 N·m	N·m (18 lb in)	do not overtighten, replace indicator annually
Torque	Auxiliary Oil Filter Drain Plug	70 ± 14 N·m	N·m (50 ± 10 lb ft)
Torque	Oil Filter Cover Nuts	100 ± 15 N·m	N·m (75 ± 11 lb ft)	tighten sequentially around cover
Torque	Oil Pan Drain Plug	145 ± 15 N·m	N·m (105 ± 10 lb ft)
Torque	Spark Plug	68 ± 4 N·m	N·m (50 ± 3 lb ft)	install by hand until spark plug bottoms out, then torque

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

Fluid	Grade	Standard	Ambient	Notes
Coolant	Cat DEAC			Diesel; 3,000 Service Hours or Three Years; annual S·O·SSM Level 2 coolant sampling and analysis
Coolant	Cat ELC			Diesel; 12,000 Service Hours or Six Years; add Cat ELC Extender at 6,000 service hours or one half of service life; annual S·O·SSM Level 2 coolant sampling and analysis
Coolant	Cat NGEC			Natural Gas; 16,000 Service Hours or Three Years; use interval that occurs first
Engine oil	Cat NGEO			Natural Gas
Engine oil	low sulfated ash oil			Required for U.S. EPA Tier 4 Final, EU Stage IV engines.
Engine oil	Cat Arctic DEO SYN SAE 0W-30		-40°C to 30°C	Engine Crankcase; Industrial Engines
Engine oil	Cat DEO SYN SAE 5W-40		-30°C to 50°C	Engine Crankcase; Industrial Engines
Engine oil	Cat DEO SAE 10W-30		-18°C to 40°C	Engine Crankcase; Industrial Engines
Engine oil	Cat DEO SAE 15W-40		-9°C to 50°C	Engine Crankcase; Industrial Engines
Fuel		Ultra Low Sulfur Diesel (ULSD)		Contains less than or equal to 15 parts per million sulfur (mg/kg); required for U.S. EPA Tier 4 Final, EU Stage IV engines. B20 biodiesel capability available.
Grease	Cat Generator Set Grease			Part Number 108-8611
Grease	MPGM			Actuator Control Linkage grease fittings
Other	Nondetergent SAE 10W oil (above 0°C/32°F) or air tool oil (below 0°C/32°F)		above 0°C	Air Starting Motor Lubricator bowl oil

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

Engine Oil Filter - Change (Primary) maintenance

⚠ Hot oil and components can cause personal injury; do not allow hot oil or components to contact skin.

Connect a hose to the drain and route to a suitable container
Open the drain valve, remove the plug, allow oil to drain, clean and reinstall plug, close drain valve
Remove 12 nuts, washers, and bolts; remove cover and gasket without damaging it
Remove nut, spring retainer, and spring while holding the spring retainer as the nut is loosened
Remove bolt, washer, spider, and plate; remove and inspect oil filter elements, clean housing interior
Ensure plug is tight; install drain plug and tighten to 70 ± 14 N·m (50 ± 10 lb ft)
Install plate, spider, washer, and bolt; install spring and spring retainer and nut; tighten nut until spring retainer bottoms out without overtightening
Fill oil filter housing with oil per Refill Capacities and Recommendations
Inspect cover gasket for damage, replace if needed, install cover
Install twelve bolts, washers, and nuts; tighten sequentially to 100 ± 15 N·m (75 ± 11 lb ft)
Install vent plug

Engine Oil and Filter - Change maintenance

⚠ Engine damage can occur if crankcase is filled above the FULL mark on the dipstick.

If equipped, open the oil drain valve and drain oil, then close the valve
If equipped with a dirty-oil pump, connect a hose and pump the crankcase empty
If no drain valve or pump, remove the oil drain plug, drain oil, clean plug and fitting, reinstall and tighten drain plug to 145 ± 15 N·m (105 ± 10 lb ft)
Replace the engine oil filter elements before filling the crankcase with new oil
Remove the oil filler cap, fill crankcase through the oil filler tube only per Refill Capacities and Recommendations, clean and install filler cap
Close the fuel supply line and crank the engine until oil pressure gauge indicates 70 kPa (10 psi); allow starting motor to cool 2 minutes before cranking again
Start the engine and operate at low idle for two minutes to fill lubrication system and filters; inspect for leaks
Stop the engine and allow oil to drain back into the sump for a minimum of ten minutes
Check oil level with the oil level gauge; maintain between ADD and FULL marks on the ENGINE STOPPED side

Ignition System Spark Plugs - Check/Adjust/Replace maintenance

⚠ Ignition systems can cause electrical shocks; avoid contacting ignition system components and wiring during operation.

⚠ Do not overtighten spark plugs - can crack shell/deform gasket.

Tools: 142-5055 Insulation Testing Group, 9U-7516 Spark Plug Gauge

Remove the spark plug
Inspect the spark plug for deposits and damage
Clean the spark plug using glass beads (do not use a wire brush)
Measure spark plug resistance with the 142-5055 Insulation Testing Group; discard if resistance exceeds specification (~1000 ohms for 146-2588, ~500 ohms for 194-8518)
Set electrode gap using the 9U-7516 Spark Plug Gauge: 0.29 ± 0.03 mm (0.011 ± 0.001 in) for compression ratio >9:1, or 0.35 ± 0.03 mm (0.014 ± 0.001 in) for compression ratio ≤9:1
Install a new 9Y-6792 Spark Plug Gasket if reinstalling a used spark plug
Install spark plug by hand until it bottoms out, then tighten to 68 ± 4 N·m (50 ± 3 lb ft)
Lubricate O-ring seal with dielectric grease or silicone lubricant, install transformer and connect wiring harness
Install the valve cover

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

Which generators use the Caterpillar G3500 engine?

The Caterpillar G3500 powers 8 generator set(s), including Caterpillar G3508 TA, Caterpillar G3512 TA, Caterpillar G3512E, Caterpillar G3516 NA, Caterpillar G3516B.