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G3520CG3520C

INTRODUCTIONINTRODUCTION

!SIGNIFICANT COMPETITIVE ADVANTAGES

!EMISSIONS

!POWER DENSITY

!EFFICIENCY

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G3520CG3520C60 Hz,1800 RPM

50 Hz,1500 RPM

NOx levels 0.5 & 1.0 g/bhp hr

Successful reliability

tests on three fieldunits (Germany,

Denmark, and SaltLake City)

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G3520CG3520C

Materials on the Web SiteMaterials on the Web Site!LEXE 3883 Product news, Cat G3520C

!LEHE 2832 G3520C 60Hz 130 Deg F Spec Sheet

!LEDE 2779 An idea whose kilowatt hour

has come brochure

!LEDE 2817 G3520C Product brochure

!234-1955 Installation drawing (access via XREF)

!New service manual available

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G3520CG3520C

Engine DesignEngine DesignDesign simplicity

Economic potential

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G3520CG3520C

ElectronicElectronic ControlsControls

SYSTEM OPERATION

Master ECM Slave ECM

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G3520CG3520C

ElectronicElectronic ControlsControlsMASTER ELECTRONIC CONTROL MODULE (ECM)

Environmentally sealed

Controls most of engine functions

Supports governing of engine Controls detonation sensors left bank

Controls ignition for left bank

Air/Fuel ratio control

Start/Stop control

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G3520CG3520C

ElectronicElectronic ControlsControls

SLAVE ELECTRONIC CONTROL MODULE (ECM)

Environmentally sealed

Controls ignition for right bank

Controls detonation sensors on right bank

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G3520CG3520C

Electronic ControlsElectronic Controls

GOVERNS THE ENGINE RPM Actual speed is detected via engine speed/timing

sensor

ECM communicates with the throttle via the CAN

data link (standard type)

Used only with the fuel valve and throttle on theC model

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G3520CG3520C

Electronic ControlsElectronic Controls

CONTROL OF IGNITION

Each cylinder has an ignition transformer

ECM sends a pulse of approximately 108 volts to

the primary coil

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Electronic ControlsElectronic Controls

Input from the customer

Gas analysis required

Caterpillar software, LEKQ6378

Program the ECM

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Electronic ControlsElectronic Controls Density of air/fuel mixture in manifold

ECM calculates actual density

Actual density compared to desired density

Continual process with loads greater then 25%

Configuration parameter programmed into ECM

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G3520CG3520C

Start/Stop ControlStart/Stop ControlParametersParameters

Cycle crank time

Engine over crank time

Engine pre-lube time out period

Engine speed drop time

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G3520CG3520C

Start/Stop ControlStart/Stop ControlParametersParameters

Driven equipment delay time

Engine purge cycle time

Engine cool down duration

Crank terminate speed

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G3520CG3520C

Monitoring SystemMonitoring System

MASTER ECM

Monitors engine operation

Monitors electronic system Generates fault codes

Issues warning codes

Shuts down engine depending on severity

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G3520CG3520C

Monitoring SystemMonitoring SystemINTEGRATED TEMPERATURE SENSING MODULE

(ITSM) Monitors cylinder

thermocouples

Monitors turbochargerthermocouples

Sends signals regarding

parameters to the ECM Open circuits cause diagnostic codes

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G3520CG3520C

Monitoring SystemMonitoring System

PARAMETERS

Low system voltage

High engine coolant temperature Low engine coolant temperature

Engine over speed High engine oil temperature

High oil filter differential pressure

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G3520CG3520C

ELECTRONIC IGNITION SYSTEM

Ignition transformers

Spark plugs

(Holes are offsetfor swirling action)

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G3520CG3520C

Fuel SystemFuel SystemAIR/FUEL RATIO

Raptor

Fuel metering device

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Air Inlet and ExhaustAir Inlet and Exhaust

AFTERCOOLER

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G3520CG3520C

Air Inlet and ExhaustAir Inlet and Exhaust

COMPRESSOR BYPASS

SURGE PROTECTION

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Air Inlet and ExhaustAir Inlet and Exhaust

EXHAUST MANIFOLD

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Air Inlet and ExhaustAir Inlet and Exhaust

TURBOCHARGER

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Lubrication SystemLubrication System

PISTON COOLING

JETS

SPIN ON FILTERS

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Cooling SystemCooling SystemJacket water pump SCAC pump

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Cooling SystemCooling SystemJacket water pump SCAC pump

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G3520CG3520C

Basic EngineBasic Engine

CYLINDER BLOCK, LINERS, HEADS

Pistons, rings and connecting rods

Crankshaft

Camshaft

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G3520CG3520C

Electrical SystemElectrical System

24 VDC power supply30 Amps continuous power

Starting motor protection Will not engage above 0 rpm

Starting motor disengages @300 rpm (adjustable by

customer)

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G3520CG3520C

SUMMARY

Fuel efficiency

O2 sensorCharge density

TurbochargersExhaust wrap

Two stage aftercooler

Various attachments

Raptor

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G3520CG3520C

Fuel EfficiencyFuel Efficiency

Big advantage over the A and B engines

Production expected in 3rd or 4th quarter

Retrofits for the B models available

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G3520CG3520C

OO22 SensorSensorG3520C

No O2 sensor Patented Charge Density system

Periodic calibration unnecessary

G3520B

O2 sensor will be eliminated Warranty costs reduced

Maintenance costs reduced

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G3520CG3520C

50 Hertz SingleTurbocharger

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G3520CG3520C

Segmented Exhaust WrapSegmented Exhaust Wrap

SPRING CLIPS SECURE INDIVIDUAL PIECES

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Outboard Exhaust WrapOutboard Exhaust Wrap

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Segmented Exhaust WrapSegmented Exhaust Wrap

PRE-FORMED AND FITTEDEXHAUST WRAPS

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Two Stage AftercoolerTwo Stage Aftercooler

FIRST STAGE JWAC

SECOND STAGESCAC/OC

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Ignition SystemIgnition SystemMaster ECM

Left side

Slave ECM

Right side

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Ignition SystemIgnition System

DRY COIL

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Ignition SystemIgnition System

PRE COMBUSTION

CHAMBER SPARK PLUG

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Crankcase BreathersCrankcase Breathers

NOT ON THE VALVECOVERS

TWO SETS ON REARCORNERS

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ThermostatsThermostats

TOP HOUSING USES 8

THERMOSTATS FOR

INCREASED FLOW.

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G3520CG3520C

Integrated TemperatureIntegrated TemperatureSensing Module (ITSM)Sensing Module (ITSM)

4

THERMOCOUPLES

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G3520CG3520C

RaptorRaptor Feedback sensors monitor

Fuel pressure Fuel temperature

Pressure differential

Regulates and meters fuel

Mounted on or close to engine

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G3520CG3520C

Questions/ DiscussionQuestions/ Discussion

Seize the moment o f exc i ted cur iosi ty on

any sub ject to solve your doubts ; for i fyou let it pass , the desire may never

return , and you may remain in ignorance.