Cat Lebw0009-00

APPLICATION
AND
INSTALLATION
GUIDE
TECHNICAL INFORMATION
G16CM34 ENGINES
G16CM34
Contents
Engine Description ............................................................ 2
General Engine Data.......................................................... 4
Emissions ........................................................................ 6
Sound Level Data ............................................................. 7
Airborne Sound Level Linear Decibels (dB) ....................... 7
Airborne Sound......................................................... 7
Exhaust Sound Level Linear Decibels (dB) ........................ 7
Exhaust Sound ......................................................... 7
Combustion Air Sound Level Linear Decibels (dB) ............. 8
Combustion Air Sound............................................... 8
Engine Startup Cycle......................................................... 9
GCM34 Starting Time................................................ 9
Engine Load Strategy .......................................................10
Lubrication Oil .............................................................10
Jacket Water...............................................................10
Speed / Load Ramp ......................................................10
Engine Heat Balance ........................................................12
Engine Derate Information.................................................14
Fuel Quality Derate ......................................................14
Altitude Derate ............................................................15
Ambient Air Temperature Derate ...................................16
Scope of Supply ..............................................................17

General.......................................................................17
Minimum Scope of Supply ............................................17
Optional Supply ...........................................................18
Gas Engine Auxiliary Systems ...........................................18
Combustion Air System ................................................19
General...................................................................19
Scope Considerations ...............................................19
Combustion Air Inlet Filter.........................................20
Connection of Turbocharger Air Inlet ..........................21
Exhaust Gas System ....................................................22
General...................................................................22
Scope Considerations ...............................................23
Exhaust System Design ................................................24
Crankcase Ventilation System .......................................24
Fuel System ................................................................26
Gas Regulating Unit (Fuel Skid)..................................28
Main Fuel Gas Line...................................................28
Pre-Chamber Fuel Gas Line........................................28
Compressed Air Supply for Fuel Skid..........................29
Fuel Quality.................................................................30
Fuel Quality Information............................................30
Auxiliary Skid ..............................................................31
Lubricating Oil System..............................................32
Cooling Water System ..............................................35
Flex Connection Installation ..........................................40

Air Consumption of the Instrumentation .........................41
Starting Gas/Air System ...............................................41
Gas Starters T112-V ................................................42
Air Starters T121-V .................................................42
Engine Barring Device...................................................44
Engine Electric.................................................................45
Engine Speed Governing ...............................................45
Fuel Flow Calculation ...................................................45
Open-Loop Fuel-Flow Calculation ...............................45
Closed-Loop Fuel-Flow Calculation .............................45
Engine Control and Monitoring.......................................45
Engine Control Module (ECM) ....................................45
Parameters Management...........................................46
Local Control Panel ......................................................47
Network Communication...........................................47
Ethernet..................................................................47
Modbus ..................................................................48
ControlNet ..............................................................48
Wiring ........................................................................48
Cable Plan Diagram (Example Only) ............................50
Cable Plan Description (Example Only)........................51
List of Wires for a GCM34 Application .......................54
PLC System ................................................................61
Engine Derate..............................................................61
Switches & Lamps .......................................................61

Summary Alarm Lamp (SAL) .....................................61
Summary Shutdown Lamp (SSL)................................61
Engine Running Lamp (ERL).......................................61
Reset Push Button (RPB)...........................................61
Engine Control Switch (ECS) .....................................62
Emergency Stop ......................................................62
Control Concept between the Engine and Compressor......62
Grounding ...................................................................63
Grounding Electrode System .....................................63
Grounding Electrode Conductors ................................64
Sizes and Materials of Alternating Current Grounding
Electrode Conductor.................................................64
Sizes and Materials of Direct Current Grounding Electrode
Conductors .............................................................64
Engine Block ...........................................................64
Fuel Skid.................................................................65
Auxiliary Skid ..........................................................65
Air Filter .................................................................66
Local Control Panel ..................................................66
Crankcase Ventilation...............................................67
GCM34 Gas Engine Factory Acceptance Test (FAT).............67
Standard FAT Measuring Points (Test Cycle) ...............68
Installation Recommendations ...........................................68
Engine Lifting ..............................................................69
Engine Mounting..........................................................70
Engine Block Foundation ...........................................70
Tightening Forces ....................................................71
Thermal Expansion.......................................................72
Alignment Specification ............................................73
Static Load .............................................................73
Center of Gravity .........................................................75
Center of Gravity .........................................................76
Auxiliary Systems Basic Data ........................................77
Installation Recommendation .........................................77
Flushing and Cleaning the Interconnect Piping .............77
Caterpillar System Filter Requirements........................78
Engine Vibration ..............................................................80
Torsional Vibration Limit ...............................................80
Torsional Vibration Analysis (TVA) Information................81
Measurement Locations ............................................81
Flywheel and Damper Information ..............................82
Crankshaft Stress Limits ...........................................83
Coupling .....................................................................83
General Installation Guidelines ...........................................84
Installing the Equipment................................................84
Specific Installation ..........................................................86
List of Standard Installation Drawings ............................87
Mechanical Installation Drawings ...............................87
Electrical Installation Drawings ..................................88
Engine Shipping and Preservation ......................................90

Engine Transportation...................................................90
Storing the Equipment ..................................................90
Engine Preservation......................................................90
N 576-3.2 Tectyl Heavy- Duty Outside Preservation ....91
N 576-3.3 Engine Inside Preservation .........................91
Painting ..................................................................91
Appearance of the Engine .........................................91
N 576-4.3-Painting ..................................................92
N 576-5.2 VCI Packaging .........................................92
N 576-5.2 Suppl.1, Information Panel for VCI
Preservation and Inspection.......................................92
N 576-5.1 Corrosion Protection Period, Check and
Preservation ............................................................92
Foreword
This section of the Application and Installation Guide lists Technical
Information for Caterpillar engines listed on the cover of this section.
Additional engine systems, components and dynamics are addressed in other
sections of this Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references.
Systems and components described in this guide may not be available or
applicable for every engine.
Information contained in this publication may be considered confidential.

Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
CAT, CATERPILLAR, their respective logos and Caterpillar Yellow, as well
as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission.
2010 Caterpillar
All rights reserved.
Application and Installation Guide
Technical Data G16CM34 Engines
Technical Information G16CM34 Engines

This guide provides technical data for the Caterpillar GCM34 engines
offered to the Petroleum Market. At the time of publishing, this data is
correct; updates will be included periodically and this section republished.
Dealers may use the Technical Marketing Information system for the most
current data.
GCM34 engines were designed with additional emphasis on reliability and
low operational cost through longer maintenance intervals and low lube oil
consumption. The design features include:
Reduced number of components
Simple maintenance, assembly and dismantling
Under-slung crankshaft
Split connecting rod for rapid and error-free assembly
Long-stroke technology
The most renowned feature is the long-stroke, which improves

combustion, lowers emissions, and reduces fuel consumption. With their
improved combustion, GCM engines provide market-leading efficiency.
2010 Caterpillar
Page 1
Engine Description
The compact cylinder head is manufactured from nodular cast iron for high
rigidity, using the proven double-deck design. The head is mounted on the
cooling water distributor, sealing between cylinder head, cooling water
distributor and engine block is provided by means of o-rings and hydraulically
tightened studs. Lube oil supply- and pre-chamber gas fuel supply lines are
attached to the cylinder head block. A plug in socket for cooling water return
from cylinder head into the cooling water distributor is provided for easy
dismantling and assembly.
Combustion air is compressed in the high efficiency turbocharger and
passed through a two-stage charge air cooler (aftercooler).
The compressor side of the turbocharger is equipped with a water wash
system. The engine lubricating oil system provides lubrication of the
turbocharger.
The exhaust gases from the individual cylinders flow through an exhaust
manifold (one per cylinder bank) to the turbine side of the turbocharger. On
the GCM34 engines, the turbocharger is mounted on the charge air cooler
(after cooler) housing at the free end of the engine. The GCM34 engine
uses two turbochargers.
A multifunction cooling water distributor is located between the engine
block and each cylinder head to provide cooling of the upper section of the
cylinder liner and the cylinder head. They are bolted to the engine block and
tightened against the cylinder head.
The engine block is a single piece rigid construction made from nodular
cast iron. All cooling occurs in the cooling water distributor and cylinder head
resulting in a water free block (dry engine block). Combustion air ducting
manifold and lube oil piping are cast, and the main oil galleries are drilled into
the block. Large inspection doors provide good access for maintenance.
The crankshaft is manufactured from heat-treated, alloy steel and is
mounted under the block (under-slung). The powerful main bearing trunions
and the generous width of the crankshaft main bearings ensure low bearing
loads and extended bearing life. By integrating gearing, and damper space
within the block, numerous bolted connections are avoided, noise is
dampened and vibration is reduced. Only four gear assemblies are required
for the timing train.
The camshaft is made up of individual segments per cylinder. This
combined with single piece camshaft sleeve bearings provide for easy
servicing. Roller camshaft followers reduce camshaft wear.
The pistons are two part pistons, a forged piston crown with chromium
plated piston grooves and steel skirt.
Page 2
2010 Caterpillar
The cylinder liners are manufactured of a natural hardened centrifugal cast

iron for minimum wear and good lubricating properties.
An anti-wear ring in the upper section of the liner provides stability and
prevents carbon build-up at the piston crown.
The Engine Control Module (ECM) controls the speed governor, ignition
timing, air/fuel ratio control, fuel pressure and detonation, and provides all
monitoring and protection. The ECM is a combination of one master and two
slave modules. Two Integrated Combustion Sensing Modules (ICSM), one for
each bank, monitor the cylinder burn time, the cylinder exhaust port
temperature, and the turbocharger inlet and outlet temperatures.
2010 Caterpillar
Page 3
General Engine Data

System Description
Metric (English)
G16CM34
Cylinder Bore
mm (in)
340 (13.4)
Stroke
mm (in)
420 (16.5)
Displacement/Cylinder
L (in3)
Total Displacement
L (in3)
Rated Speed
rpm
38.1 (2325)
610 (37209)
450 to 750
Engine Power @ 750 rpm

kW (hp)
6100 (8180)
Engine Power @ 450 rpm

kW (hp)
3662 (4910)
Firing Order CCW
A1B3A3B5A5
B7A7B8A8B6A6
B4A4B2A2B1
Combustion Air Flow

Nm/hr (scfm)
32220 (20044)
Exhaust Flow
Nm/hr (scfm)
33520 (20853)
Engine operation altitude limit w/o derate

m (ft)
Combustion air temperature limit w/o derate
C (F)
Compression Ratio
Mean Effective Pressure
Bar (psi)
Engine Efficiency
Crank Radius
mm (in)
Connecting Rod Length
mm (in)
Page 4
900 (2952)
38 (100)
11.4:1
16 ( 232)
Up to 43.5% (ISO
30461/1)
210 (8.3)
985 (38.8)
2010 Caterpillar
System Description
Metric (English)
Reciprocating Weight
N (lbs)
G16CM34
1804 (405.6)
Lubricating Oil Capacity (Deep Oil Pan)

m3 (gallon)
2.5 (660)
Lubricating Oil Consumption

g/kWh (gal/hr) at full load 50%
0.3 (0.36)
Engine Dimensions (Length/Width/Height)

mm (in)
8405/2992/3875
(331/118/153)
Dry weight
kg (lb)
82000 (180779)
Wet weight approx. (including lubricating oil

and water content)
kg (lb)
86500 (190700)
2010 Caterpillar
Page 5
Emissions
Emissions are typically measured as concentration-based units such as ppm
(parts per million), dry at actual oxygen content. Measured emission data is
recalculated for each agencys requirement:
Primary pollutants from natural gas-fired reciprocating engines are (NOx),
carbon monoxide (CO), and volatile organic compounds (VOCs unburned,
non-methane hydrocarbons or NMHC). Formation of NOx is exponentially
related to combustion temperature in the engine cylinder. Carbon monoxide,
NMHCs and NMNEHCs are primarily a result of incomplete combustion.
The GCM34 engines are designed to operate at following not to exceed
settings.
0.5 gNOx/bhp and hour
0.7 gNOx/bhp and hour

Standard Emission Values for NOx Setting
(at test bench norm conditions)
Unit
Value
Oxygen
13.0
CO
g/bhp-hr
4.0
NMHC
g/bhp-hr
0.55
NMNEHC
g/bhp-hr
0.35
HCHO
g/bhp-hr
0.16
THC
g/bhp-hr
9.50
Notes: These values are only for reference purposes.
Emissions data are site specific and vary with altitude,
temperature, fuel composition and NOx setting.
Site specific emission calculations are available upon
request.
Page 6
2010 Caterpillar
Sound Level Data

Airborne Sound Level Linear Decibels (dB)
Measurement Geometry
Metric (English)
G16CM34
Measurement Surface Area

m2 (ft2)
220.16 (2369.7)
Measurement Segments
Distance to Adjacent Walls
m (ft)
19
1.5 (5)
At Long Side: 1 (3.2)
At Head Side: 1 (3.2)
At Top Side: 0.5 (1.6)
Measurement Distances From Engine

m (ft)
Sound Data
Airborne
Sound
Sound Level in Linear Decibels (dB)

"Octave Band Center Frequency"
31.5
Hz
63
Hz
125
Hz
250
Hz
500
Hz
1
kHz
2
kHz
4
kHz
8
kHz
Linear
[dB]
A-weighted
[dB(A)]
N/A
115
114
117
114
111
110
115
105
119
123
Airborne Sound
Sound power measurement according to ISO 9614-2 (Intensity
scanning)
Sound power level (dB re 1e-12W)
Exhaust Sound Level Linear Decibels (dB)

Sound Data
Exhaust
Sound

31.5
Hz
63
Hz
125
Hz
250
Hz
500
Hz
1
kHz
2
kHz
4
kHz
8
kHz
Linear
[dB]
A-weighted
[dB(A)]
139
146
140
129
134
129
127
127
100
148
136
Exhaust Sound
scanning)
Measuring point is at 3 m [9.8 ft] after the turbocharger, at the open

pipe.
2010 Caterpillar
Page 7
Combustion Air Sound Level Linear Decibels (dB)

Sound Data
Exhaust
Sound

31.5
Hz
63
Hz
125
Hz
250
Hz
500
Hz
1
kHz
2
kHz
4
kHz
8
kHz
Linear
[dB]
A-weighted
[dB(A)]
N/A
81
89
100
109
120
113
136
127
136
137
Combustion Air Sound

scanning)
A weighted Sound Power Spectrum is available on request.
Page 8
2010 Caterpillar
Engine Startup Cycle
Minimum Start Time from stop to full load: 205 seconds.
Standard Start Time from stop to full load: 880 seconds.
Compressors typically get loaded in a single load step from approx. 10

20 % to 100%. The first 10 20 % is a function of the size of the
compressor by-pass valve that re-circulates the compressed gas and
gradually increases load on to the engine as engine speed is increased. It is
recommended that the driven compressor bypass circuit be the same size as
the compressor discharge piping for ease of starting and loading the engine.
Engine Startup Cycle
GCM34 Starting Time

Minimum
Start Time
[sec]
Standard
Start Time
[sec]
Speed
[1/min]
Engine load
[%]
120
240
Purging
20
30
80
Starting
10
10
350
Speed ramp
40
150
750
Load ramp
15
450
750
100
Total time
205
880
Exhaust
ventilation/
pre lubrication
2010 Caterpillar
Page 9
Engine Load Strategy

The G16CM34 can be operated continuously from 100% down to 50%
torque capability. In this torque range is no time limit of operation.
For a short period time the engine is capable operate down to 20% of rated
torque. For every hour of low load, 12hours of full load must follow.
Lubrication Oil
Minimum lube oil temperature for engine starting ....................... 5C (41F)

Minimum lube oil temperature to perform a minimum start time 27C (81F)
Minimum lube oil temperature before loading the engine ......... 40C (104F)
Minimum pre-lubrication oil pressure before start................. 0.5 bar (7.2 psi)
Jacket Water
The minimum cooling water temperate before start ................ 40C (104F)
Before loading the engine from 50% to 100%, the cooling water
temperature must be above ................................................. 50C (122F)
Recommended preheat cooling water temperature.................. 50C (122F)
For the Minimum Start Time, the engine must be preheated .... 80C (176F)
Speed / Load Ramp
Speed ramp recommended ................................................... 2 - 4 rpm/sec

Speed ramp maximum rate* .................................................... 10 rpm/sec
Load ramp recommended .................................................0.36% rated/sec
Load ramp not to exceed** .................................................. 3% rated/sec
* temperature must be stabilized at 80C (176F)
** temperature must be stabilized at 80C (176F) and engine must be at
full rated speed of 750 rpm; engine speed can drop down to minimum of
450 rpm during the loading sequence.
On the following diagrams the maximum torque curves, as well as a
starting curve with unloaded compressor, can be found. These are to be
considered as not to exceed values within engine operation.
Maximum torque during startup may not exceed the load curve in the graph
below.
Page 10
2010 Caterpillar
Maximum Allowed Start up Torque

Engine
Speed
RPM
Torque
ft-lb
Torque
N-m
Equivalent
bhp
Equivalent
bkW
MAXIMUM ALLOWABLE START UP TORQUE LOADS

3200
4339
0
75
2100
2847
30
22
150
2815
3817
80
60
225
4000
5423
171
128
300
5670
7687
324
241
375
7810
10589
558
416
450
10450
14168
895
668
**Please refer to maximum engine load ramp-up and engine loading

recommendations**
450
57284
77667
4908
RECOMMENDED START UP TORQUE LOADING

3200
4339
0
3660
75
2100
2847
30
22
150
2815
3817
80
60
225
4000
5423
171
128
300
5670
7687
324
241
375
7810
10589
558
416
450
10450
14168
895
668
525
13550
18371
1354
1010
600
17185
23300
1963
1464
675
17185
23300
2209
1647
750
17185
23300
2454
1830
**Please refer to maximum engine load ramp-up and engine loading

recommendations**
750
2010 Caterpillar
57284
77667
8180
6100
Page 11
Engine Heat Balance

The engine heat balance is provided to properly size the radiators and heat
recovery systems for the high temperature (HT) and low temperature (LT)
circuits.
The general heat balance information under ISO conditions for the
G16CM34 is shown below.
Heat rejection factors are subject to change with ambient temperatures and
elevation.
The project specific heat rejection calculations are provided for each site as
part of the Caterpillar scope of supply.
Maximum coolant water temperature at the inlet 2nd stage after cooler.
SCAC inlet = Maximum 45C (113F)
Engine derate when temperature exceeds 45C (113F)
Page 12
2010 Caterpillar
G16CM34 Engine Heat Balance

(site specific can vary)
2010 Caterpillar
Page 13
Engine Derate Information

The following derate values apply to the G16CM34 engines.
Temperature and altitude derates must be considered together and the
larger derate of altitude and temperature or fuel quality derate must be
applied.
Fuel Quality Derate

Special rating request is necessary for Cat Methane Number <55 or
>100.
Low Heating Value must be in a range of
Greater than 31.5MJ/Nm3 (800 BTU/SCF) and
Less than 43,3 MJ/Nm3 (1100 BTU/SCF)

G16CM34 Fuel Derate
Fuel Derate Factor
0.95
0.9
0.85
55
60
65
70
75
80
85
90
95
100
Caterpillar Methane Number
Methane Number
Fuel Derate Factor
55
56
58
60
62
64
66
68
70 - 100
0.85
0.86
0.88
0.90
0.92
0.94
0.96
0.98
1.00
Valid for: Altitude <900 meters (2952ft.), Ambient Temperature

<=38C (100F), SCAC temperature <=45C (113F)
Page 14
2010 Caterpillar
Altitude Derate
Altitude derate factor
G16CM34 Altitude Derate

1,000
0,980
0,960
0,940
0,920
0,900
0,880
0,860
0,840
0,820
0,800
0
500
1000
1500
2000
2500
3000
3500
Elevation in m
Elevation
Derate Factor
Feet
Meters
1.000
820
250
1.000
1640
500
1.000
2460
750
1.000
2953
900
1.000
3280
1000
0.994
4101
1250
0.976
4921
1500
0.958
5741
1750
0.941
6561
2000
0.923
7381
2250
0.905
8202
2500
0.888
9022
2750
0.870
98042
3000
0.852
10663
3250
0.835
11482
3500
0.817
Valid for: MN>=70, Ambient Temperature <=38C (100F), SCAC temperature

<= 45C (113F)
2010 Caterpillar
Page 15
Ambient Air Temperature Derate

Temperature Derate Factor
G16CM34 Temperature Derate

1.000
0.980
0.960
0.940
0.920
0.900
0.880
15
20
25
30
35
40
45
50
Temperature in C
Ambient Temperature
C
F
100
15 - 38
102
39
104
40
106
41
108
42
110
43
111
44
113
45
115
46
117
47
118
48
120
49
122
50
Temperature Derate
Factor
1.000
0.994
0.987
0.981
0.974
0.968
0.956
0.944
0.932
0.920
0.908
0.896
0.884
Valid for: MN>=70, altitude <700m ( 2297 ft.)
Page 16
2010 Caterpillar
Scope of Supply
General
A minimum standard scope of supply, and a list of options, has been

established for gas compression applications of the GCM34 engines.
The minimum scope of supply permits standardization of engine
components and engine auxiliaries for a wide range of gas compression
requirements under diverse site conditions.
The list of options reflect engine auxiliary components which may be
included as part of the engines scope of supply or may be supplied by the
customer.
Minimum Scope of Supply
The following outlines the Caterpillar minimum scope of supply of engine

auxiliary systems:
Engine mounted air/gas starters
Engine mounted air driven barring device
Engine mounted oil pump
Flexible coupling
Caterpillar will conduct the Torsional Vibration Analysis (TVA) based

on the customer provided compressor data.
Flexible connectors, DIN to ANSI adapters for all the engine

connection points.
Remote mounted fuel regulating skid
Remote mounted engine auxiliary skid for cooling and lubricating oil
supply:
Cooling water pumps and temperature control valve
Oil filters, oil cooler and temperature control valve
Lubricating oil preheating system
Cooling water preheating system
Prelubrication pump
Remote mounted crankcase ventilator with filter
Remote mounted Local Control Panel
Air Inlet filters
2010 Caterpillar
Page 17
Optional Supply
The following components are required for normal engine operation and
considered customer supplied equipment. Equipment listed herein can be
quoted and included in the Caterpillar scope of supply at the customers
request:
Complete exhaust systems with silencers
Complete air inlet system
Heat recovery system
Radiator
Engine skids and/or foundation
Engine shelter
Gas Engine Auxiliary Systems

Auxiliary systems are required for operation of the GCM34.
All required equipment is included in the Caterpillar standard scope of
supply. This chapter gives a brief description of the standard auxiliary
systems.
This section provides a brief description of the standard auxiliary systems.
Detailed information of components and processes of the auxiliary systems
can be obtained from the attached Balance of Plant (BoP) and Process
Installation Drawings (PID) included in the appendix of this document.
Combustion air system
Exhaust gas system
Fuel system
Lubrication oil system
Cooling water system
Starting air/gas system
Engine turning device
Coupling
Electrical system (3 phase power / AC/DC)
Local Control Panel
Page 18
2010 Caterpillar
Combustion Air System

General
The G16CM34 engines have two turbochargers, which compress intake air
into a common intake manifold. The engine exhaust gases which are
collected in two separate exhaust manifolds, one for each bank, drive the
turbochargers. The compressed air is cooled in a two-stage after-cooler
before reaching over the common intake manifold the combustion chamber.
Combustion air must be clean and cool; therefore special considerations in
terms of temperature and quality are required. Air-borne debris is the major
source for contamination and engine wear.
Inlet air must always be filtered by a sufficient air filter system that is
adequate for the pollution of the air for area.
Scope Considerations
The Caterpillar supplied air filters are dry paper element type filters
enclosed in a carbon-steel housing for outdoor installation. The air filter
intake includes a protective rain. The design is made for normal dust areas.
In extremely dusty areas the filter element lifetime will be reduced, an
alternate filtration system must be considered.
Oil bath filters are generally not allowed.
A differential pressure transmitter across the filtering elements provides
filter restriction information. Engine performance will be adversely affected
by excessive pressure drop (restriction) over the air intake system; therefore
regular maintenance of the air filters is important.
A temperature element provides information on ambient air intake
temperature.
An inlet air preheater is recommended in areas where ambient temperatures
are below 20C (-4F) for an extended period of time.
2010 Caterpillar
Page 19
Inlet Air Specification

System Description
Metric (English)
Air Temperature @ Air Cleaner, maximum
C (F)
Air Temperature @ Air Cleaner, minimum
C (F)
Air Inlet Restriction, With New Filter
Pa (psi)
Air Inlet Restriction, Not to Exceed
Pa (psi)
Air Inlet Restriction, Differential between A
and B banks, maximum
Pa (psi)
G16CM34
50 (122)
-20 (-4)
1200 (0.17)
3000 (0.453)
300 (0.045)
Combustion Air Inlet Filter

The combustion air cleaner group is to be mounted off of the engine and
provide an ample air supply to the engine through a filter system.
Cleanliness of the filtering elements is controlled via a differential pressure
transmitter directly mounted on the air filter housing.
The optional preheating device integrated into the air filter housing helps to
keep control of ambient air inlet temperature in cold climates, below 20C
(4F).
Note: A complete study of the air intake system should be performed by the
customer to minimize the hot air recirculation.
For optimal performance in regions with significant rain and/or snow, a rain
cap or snow hood is recommended to be attached to the air filter housing.
Page 20
2010 Caterpillar
The air filter housing should be installed with sufficient distance from the
exhaust stack facing outwork to prevent any re-circulation of exhaust gases
in the combustion air system.
For further technical information please refer to Auxiliary Module
information from your Caterpillar representative.
Connection of Turbocharger Air Inlet
The thermal expansion and vibration must be taken in consideration.
Therefore the air inlet connection to the engine must always use a flexible
compensator to avoid stress to the turbocharger connection. The air inlet
tube can be turned in 15 segments from 0 to 90 forward.
Do not exceed manufacture misalignment values on flexible connections.
System Description
Metric (English)
G16CM34
Air Inlet Connection

Engine Side
Bellow and Adapter

333 mm
Air Inlet Connection

Customer Side
Bellow and Adapter

16 ANSI 150#
Combustion Air Flow

Nm3/h (scfm)
32220 (20044)
Maximum Inlet Air Temperature

C (F)
2010 Caterpillar
38 (100) without derate

50 (122) with derate
Page 21
Exhaust Gas System

General
The exhaust gases from engine cylinders, which are collected in the
exhaust manifold, are used to drive the turbocharger. The GCM34 engines
have two variable geometry turbochargers that compress air into a common
intake manifold. Therefore, the GCM34 engines will have two separate
exhaust gas outlets, which should be ducted and vented to the outside.
Note: The exhaust gas outlets can be combined into a single exhaust pipe,
which must be properly sized for the total exhaust gas volume.
The exhaust pipe cannot be combined with exhaust from other engines.
Page 22
2010 Caterpillar
System Description
Metric (English)
G16CM34
Exhaust Outlet Connection

Engine Side
Bellow
DN 400

Customer Side
Exhaust Flow
Nm3/h (scfm)
Bellow
16 ANSI 150#
33520 (20853)
Maximum Exhaust Gas

Temperature After Turbocharger
(Alarm Level)
C (F)
460 (860)
Maximum Exhaust Gas

Temperature After Turbocharger
(Shutdown Level)
C (F)
480 (896)
Scope Considerations
The Caterpillar scope of supply for exhaust systems includes only the
expansion joints for the two customer connection points.
For safety reasons, it is recommended to add on an optional exhaust
system ventilator system.
Typically, an exhaust system will require, as a minimum, ducting, exhaust
silencer, expansion joints and relief valves. Systems can also include
elements like catalysts and heat recovery systems.
The exhaust piping system must be insulated in order to prevent heat
radiation.
Exhaust systems and air intake system must be separated to prevent
pollution of intake air.
Thermal expansion must be taken into account when designing supports
for exhaust systems. A steel pipe expands 0.0076 per meter and each
100F rise of exhaust temperature.
Exhaust lines must be self-supporting and cannot be attached to engine or
engine skid.
No load on the turbocharger flanges is allowed.
If a catalyst is being used the flow restriction of the catalyst must be
included in the exhaust backpressure calculation.
2010 Caterpillar
Page 23
The exhaust system backpressure limitation of 4kPa (0.58 psi) is not to be

exceeded.
Proper exhaust ventilation can greatly reduce the risk of backfiring.
Installation of rupture disks or spring-loaded relief valves in the exhaust
system will prevent damage due to backfiring. Caterpillar highly recommends
using rupture discs with all GCM34 installations.
Exhaust System Design
Horizontal expansion must be guided away from the engine by fixed

mounting on the support closest to the engine.
To avoid damages by condensate water in the exhaust line, we recommend
a slope exhaust stack with a minimum angle of 1% downward, away from
the engine.
System Description
Metric (English)
G16CM34
DN400 to 16 ANSI 150# bellow

(1 connection point per turbocharger,
total 2)
Mounting of Expansion Joints
All bellows must be mounted with

parallel flanges and without strain.
Exhaust System Backpressure,

Maximum
kPa ( psi)
4 (0.58)
Loading on Turbocharger Inlet,

Maximum
The bellows supplied by Caterpillar

account for the maximum allowable
loading on the turbocharger. All other
external piping must be self-supporting.
Do not support exhaust ducting on the
engine.
Crankcase Ventilation System
Crankcase emissions result from piston ring blow-by. The blow-by volume
varies according to cylinder pressure and component wear. Crankcase
emissions contain exhaust gases, wear particles, oil, air, natural gas and fuel
emissions.
To prevent pressure build-up within the crankcase, a ventilation system
must be installed. The ventilation system includes a carbon cyclone filter and
fan. Oil trapped in the filter will flow back to the oil sump. The fan is
necessary to maintain a slightly negative pressure within the crankcase in
Page 24
2010 Caterpillar
order to further reduce explosion risk. An engine mounted oil mist detector is
part of the Caterpillar standard scope of supply.
For engines operating in an open environment the filter fumes are expelled
to the atmosphere. In a closed environment the filtered fumes can be piped
to the engine combustion air inlet. The crankcase ventilation system, CSA
certified for operation in Class 1, Div. 2, Group D, is part of the Caterpillar
minimum scope of supply.
Install the crankcase ventilator a minimum of 1.5 m (5ft) above the oil
level.
A minimum vacuum pressure of -1 Pa (-4.00 in/H2O) must be maintained in
the crankcase. For further technical information please refer to specific
crankcase ventilation system information from your Caterpillar
representative.
2010 Caterpillar
Page 25
Fuel System
The Caterpillar GCM engine family is designed to run on natural gas and an
adequate fuel analysis must be available for correct engine rating and
configuration. The principle of the GCM-combustion is based on a
prechamber/ main chamber system. Fuel gas is ignited in the prechamber,
which distributes the ignition into the main combustion chamber of each
cylinder. Every cylinder head is equipped with a Solenoid Operated Gas
Admission Valve (SOGAV), which regulates the fuel flow through during the
inlet stroke. The master ECM controls the opening time of the SOGAV.
The prechamber has mechanical check valve.
Each engine must have its own gas pressure-regulating unit, which will
provide the correct fuel flow and pressures to the main chamber and
prechamber fuel manifolds. The fuel pressure-regulating unit is part of the
Caterpillar minimum scope of supply. The fuel-regulating unit will contain one
main fuel supply line and one prechamber supply line with:
One common gas filter (2 ) with magnetic insert
Individual pressure regulating valve with pilot valve
I/P converter, input signal 4-20 mA, 0-6 bar (0-87psi)
Electro-pneumatic shout-off valve
System Description
Metric (English)
Inlet Pressure Gas Regulation
Unit
Bar (psi)
Gas Flow Prechamber
Nm/h (scfm)
Gas Flow Main Chamber
Nm/h (scfm)
Gas Type
G16CM34
4.5 6.0 (65 87)
85 (50)
1525 (898)
Natural gas with MN 70.100
NM 55 to 69 only with derate
MN can be calculated by CAT software
The gas supplied to the fuel pressure-regulating unit must be filtered, dry,
and must meet the required pressure ranges and quality guidelines described
in the fuel quality section. Pipe sizing and distances from the gas-regulating
unit to the engine should be optimized in order to ensure correct engine inlet
fuel pressure and sufficient flow (maximum 5m (16.5 feet)).
Page 26
2010 Caterpillar
Gas pressure must be constant at all times for all operating ranges and may
not vary more than 1.7 kPa (0.25 psi).
Connection of the prechamber and main chamber lines to the engine must
be through flexible connections, which are part of the Caterpillar scope of
supply.
Note:
Maximum gas pressure: 6 bar ( 87 psi)
Minimum gas supply pressure of 4.5 bar (65 psi)
Minimum gas temperature at fuel skid inlet 0C (32F)
Maximum gas temperature 60C (140F ) at fuel skid inlet
Total gas flow 1610 Nm3/hr (950 scfm)
Maximum distance from fuel skid to engine 5m (16.5 ft)
Gas must be dry and clean

Schematic of G16CM34 Fuel System
2010 Caterpillar
Page 27
Gas Regulating Unit (Fuel Skid)

The fuel skid is an off-engine auxiliary equipment skid. It is part of the
Caterpillar standard scope of supply. The skid provides fuel gas to the engine
with the required engine fuel inlet pressure and flow. It contains a gas filter,
pressure regulating valves and safety valves.
Main Fuel Gas Line

The main fuel gas line (MC) provides a pressure regulated fuel flow to the
engines combustion chamber. It consists mainly of a pressure regulator
operated by an I/P converter. An electro-pneumatic shut-off valve (GSOV) is
mounted between the gas pressure regulator and the engines Solenoid Gas
Admission Valve (SOGAV).
Pre-Chamber Fuel Gas Line
The pre-chamber fuel gas system (PC) is identical with the main fuel gas
system, only the pressure and volume specifications are different.
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2010 Caterpillar
Compressed Air Supply for Fuel Skid

Air consumption for each I/P-Transducer is 0.42 Nm/hr (0.25 scfm). Fuel
skid has two I/P transducers; each skid will consume 0.84 Nm/hr (0.50
scfm).
Main fuel line and Pre-chamber fuel line are equipped with ElectroPneumatic shut-off valves. For each engine start, two valves (venting valves)
will cycle from open to close, and two valves (shut-off valves) will cycle
from closed to open.
Each valve will require 0.025 m (0.88 ft) for a total of 0.1 m (3.52 ft)
per each engine start.
The air supply must be instrument quality.
Note: For detailed information please refer to the specific Fuel Skid manual
available through your Caterpillar representative.
2010 Caterpillar
Page 29
Fuel Quality
Through extensive testing and field experience, Caterpillar established the

following guidelines for minimum gas fuel quality, which should be observed:
Fuel Quality Information
Quality
Metric (English)
Gas Temperature Before Engine Inlet
C (F)
Gas Pressure Before Fuel Regulating Skid
bar (psi)
Maximum Gas Pressure fluctuation
bar (psi)
Minimum Lower Heating Value 1 w/o derate
kJ/Nm (BTU/ft)
Minimum Caterpillar Methane Number w/o
derate
Maximum Sulfur as H2S
mg/kJ (ug H2S/BTU)
G16CM34
Min. 0 (32)
Max. 60 (140)
Min. 4.5 (65)
Max. 6.0 (87)
0.017 ( 0.25)
Min. 31.5 (800)
Max. 43.3 (1100)
Min. 70
Max. 100
0.43 (0.45)
Maximum Halide as Chlorine
Maximum Ammonia
Maximum Oil content
1.19 mg/kJ
Maximum Particles
0.8 mg/kJ
Maximum Silicon
0.1 mg/kJ
Maximum Water
Page 30
Not allowed as a liquid.

Vapor water content in the
gas must be always above
the deepest possible dew
point temperature of the
system.
2010 Caterpillar
Auxiliary Skid
The auxiliary equipment skid houses the following:
Cooling water pump for jacket water heater (HT)
Cooling water pump for oil cooler and charge air cooler SCAC (LT)
Duplex oil filter
Optional preheat systems for oil and cooling water
Skid mounted sensors and pneumatic valves provide control and

monitoring of each circuit.
The skid provides easy customer connection points at the skid edges for
connection points from the engine, the customer supplied radiator and the
optional inlet air pre-heater.
It is recommended to install the combined module indoor, close to the
engine, to achieve stable temperature conditions. Proper ventilation air
supply is required for adequate pump motor cooling. In cases where the
combined module is used under outdoor conditions, the ambient temperature
must be taken in consideration. In cold climate the pipes system must be
isolated to achieve the minimum start temperance for oil and water system
from preheat system.
2010 Caterpillar
Page 31
Lubricating Oil System

System Description
The engine mounted, gear driven, lube oil pump draws lube oil from the
sump through a screen in the suction pipe and pumps it towards the
combined module. Temperature control valve controls oil flow through the
auxiliary skid mounted plate and frame heat exchanger and oil flow by-pass
circuit, based on required engine oil inlet temperatures that are monitored.
The temperature sensors provide the information to an off-skid control panel,
which sends an electrical signal to the valves I/P transducer. The oil is cooled
in the plate and frame type heat exchanger using the separate after cooler
circuit cooling system, commonly referred to as the low temperature (LT)
circuit.
A duplex oil filter filters the lube oil before it returns to the engine. The
engine mounted emergency strainer provides additional protection before the
oil starts lubricating the engine.
The system requires an electric pre-lubrication pump on the combined
module, which will circulate oil from the sump to the above-described circuit
before engine start and stop sequences (post lube).
System Specific Information
The type of engine oil used has a significant influence on the service life
and performance of the engine. This greatly affects the engine cost of
operating. The appropriate engine lubricant must be used to achieve long
engine life.
The oil should reduce deposits in the engine and heat exchangers to
achieve the longest possible change interval, lowest possible oil consumption
and minimize engine wear. The base oil should be a high-quality solvent
refined product from reliable source for gas engine lubricants. It should be
resistant to oxidation and nitration, have good load carrying capacity as well
as good thermal stability. Regenerated oils may not be used.
An optional automatic oil level regulator can be installed to ensure proper
oil levels on a continuous basis. Connection points can be seen in the engine
general arrangement drawings. Even if the oil level is regulated automatically,
daily inspection of the entire lube oil system must be performed.
Interconnecting piping shall be stainless steel and pickled.
Lubricating Oil Recommendation
Caterpillar recommends the use of Caterpillar original-supplied NGEO
lubricating oil. Viscosity class SAE 40 is required.
Also refer to project related documentation for lubricating oil
recommendations.
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2010 Caterpillar
The following table lists lubricating oils for Caterpillar engines. The oils in
Column I are proven in use for Caterpillar engines. The oils in Column II are
permitted for controlled use; permission by Caterpillar is required.
System Description
Metric (English)
G16CM34
Viscosity / 40C (104F)
SAE 40
Engine Oil Temperature at engine inlet, nominal

C (F)
60 (140)
Main Oil Pump Flow Rate @ 750 rpm

m/h (gpm)
Main Oil Pump Maximum Head
bar (psi)
Pre-lubrication pump delivery
M/h (gpm)
Pre-lubrication Pump Head
bar (psi)
Oil Sump Capacity
L (gal)
2010 Caterpillar
168 (740)
10 (145)
40 (176)
5 (73)
2500 (660)
Page 33
Oil Change
Oil change intervals are dependent upon the fuel quality, environmental
conditions, operating conditions, oil consumption, engine maintenance, total
engine oil volume and quality of the oil. Oil level must be checked daily and
should be topped off regularly. As maximum interval, oil should be topped
off when 20% of the circulating volume has been used.
If a remote oil sump (external oil tank) is used, the minimum circulating oil
volume requirements are 0.50 liters/kWh (803 gal per hour) at full load.
With this circulating volume, the oil should initially be changed every 7500
hours (See book A4.05.08 of technical documentation). This interval is a
guide value only.
The lubricating oil must be changed when one of the values in the
following table are exceeded.
The pentane and heptane insolubles must not exceed 2% by weight.

SOS Lube Oil Analysis
Caterpillar recommends including sampling ports in the engine coolant
system and lubricant oil systems. The sampling port locations should be
included in the application design layout. Caterpillar recommends SOS
lubricant oil sampling before oil filter inlet.
During the first 500h the oil should be analyzed every 100h
For more than 500h it is sufficient to analyze every 150h
Refer to Caterpillar document PEHJ0191 or LEBW495.
Page 34
2010 Caterpillar
Cooling Water System

System Description
Low Temperature (LT) Aftercooler Circuit

In the separate aftercooler circuit, referred to as the Low Temperature (LT)
cooling water system, the coolant is pumped from the combined module to
the second stage of the engine mounted aftercooler, before returning to the
module. After passing through the second stage of the aftercooler, the LT
coolant is routed to the plate and frame heat exchanger mounted on the
combined module.
2010 Caterpillar
Page 35
The temperature control valve controls flow through the customer-supplied

radiator and bypass, based on required LT engine inlet temperature, which is
monitored before pump. The LT pump starts and stops with the engine.
Temperature approached for customer radiator design is 6C (11F).
LT Cooling Water System
Metric (English)
G16CM34
Maximum LT Cooling Water Inlet

Temperature SCAC
C (F)
45 (113)
Engine Derate LT Cooling Water

Temperature CAC
C (F)
<45 (<113)
LT Cooling Water Flow

m3/h (gpm)
100 - 120 (440 528)
Designed LT Cooling Water Pressure

barg (pisg)
4.5 5.0 (65 69)
Maximum LT Cooling Water Pressure

barg (pisg)
6.0 (87)
Minimum LT Cooling Water Pressure

barg (pisg)
Alarm: 4.0 (58)
Recommended Radiator Approach

Temperature
C (F)
Shutdown: 3.5 (51)

T 6 (T 11)
High Temperature (HT) Circuit or Jacket Water Circuit

The engine jacket water circuit is referred to as the high temperature (HT)
cooling circuit. The HT pump, will supply coolant from the combine module
to the engine. The primary function of the HT circuit is to provide coolant for
the engine jacked water system. The HT circuit is also used to cool down
turbocharged air in the aftercooler. After leaving the engine, the HT coolant
returns to the combined module.
An optional air inlet pre-heater system can be chosen when the air inlet
temperature gets below 20C (-4F). In that case, a customer-provided Tconnection would allow HT coolant to circulate through the air pre-heater in
the air intake housing with a return line on the combine module skid. Flow
control through this air pre-heater is accomplished through a temperature
control valve and a temperature sensor installed on the air filter, which
monitors the ambient inlet air temperature.
Page 36
2010 Caterpillar
The temperature control valve controls flow through the customer-supplied

radiator and bypass based on the required HT engine outlet temperature,
which is monitored. The HT pump starts and stops with the engine. The HTcircuit includes a pre-heating unit in order to maintain the engine temperature
for easy start-up. This unit is only in operation when the engine is stopped.
HT Cooling Water System
Metric (English)
Maximum Jacket Water Outlet
Temperature
C (F)
Maximum Jacket Water Outlet
Temperature
C (F)
HT Cooling Water Flow
m3/h (gpm)
G16CM34
90 (194)
Alarm: 93 (199)
Shutdown: 98 (208)
100 - 120 (440 528)
Designed HT Cooling Water Pressure

barg (pisg)
4.5 5.0 (65 69)
Maximum HT Cooling Water Pressure

barg (pisg)
6.0 (87)
Minimum HT Cooling Water Pressure

barg (pisg)
Alarm: 4.0 (58)
Temperature Differential Across Engine,

Jacket Water Only, Not Including First
Stage Aftercooler
C (F)
Shutdown: 3.5 (51)

T 5 - 10 (T 9 - 18)
General Information
The expansion tanks and radiator are commonly not included in the
Caterpillar scope of supply, but can be quoted and included in the scope of
supply upon customer request.
When sizing radiators, take into account the antifreeze concentration will
decrease the cooling efficiency due to the reduction of the specific heat of
the cooling water.
2010 Caterpillar
Page 37
A radiator for each cooling circuit, HT and LT, must be used. Each circuit,
HT and LT, must contain its own expansion tank.
The expansion tank volume must be calculated to the overall water volume
in each circuit.
The expansion tank volume should be 10% to 15% of the total circuit
water volume.
The engine provides various vent lines (37, 37a, 37b) in both circuits to
purge trapped air. These 1 vent lines should be connected to the top of the
expansion tank. Each circuit, HT: 37 and 37a (joined together) and LT: 37b,
should be vented to its own expansion tank. Flexible connections must be
used for all engine connection points. To provide a static pressure to the
cooling water pump, the expansion tank button must be connected to the
cooling water pump suction side and must be installed at a certain height in
the system. The pipe diameter for static pressure pipe is 2.
The water level height must be between 4.5m to 10 m (15ft to 33ft)
above the crankshaft center line. Shutoff valves are recommended for all
expansion tank connections to allow the water to be shut off if needed.
A continuous venting of the system and a continuous static pressure must
be ensured during operation.
Pre Heating and Temperature Requirements
Electric heaters in the HT cooling circuit and a circulation pump accomplish
engine preheating. Engine preheating is important for ease of starting and
quick engine load acceptance. Typically, the engine should be preheated to
temperatures ranging from 60 to 80 C (140 to 176F).
Page 38
2010 Caterpillar
The minimum cooling water temperate before start ................ 40C (104F)
Before loading the engine from 50% to 100%,
the cooling water temperature must be above......................... 50C 122F)
Recommended preheat cooling water temperature.................. 50C (122F)
For the Minimum Start Time, the engine must
be preheated to.................................................................. 80C (176F)
The jacket water pre heater is able to deliver 48 kW (2731 BTU) of heating
power.
For combined modules process diagrams, please see the attached PID
documents.
Detailed information can also be obtained from the auxiliary skid
specification sheet included in the appendix of this document.
Cooling Water Requirements
Always use clear, clean water. Key values for fresh water analysis must be
within the following ranges:
Cooling Water Requirements
Property
Total Hardness
Acidity
Chloride Ion
Content
Sulphate Ions
Total Solids
Unit
Maximum Limit
ASTM Test
mg/L
170
grains/gal
10
pH
7.5 to 8.0
mg/L
40
D512
grains/gal
2.4
D4327
mg/L
100
grains/gal
5.9
mg/L
300
grains/gal
20
D1126
D1293
D516
D1293
With low water hardness, the corrosion inhibiting effects of chemicals

generally show the best results. At higher hardness values, and without
hardness stabilization, chemicals react with the water content causing
precipitations and reducing the overall corrosion inhibiting effect. An oilbased inhibitor may be used for slightly harder water conditions.
In cases where temperatures are at or below freezing, an anti-freeze must
be added to the coolant. Only anti-freeze with corrosion inhibitor additive
may be used. To obtain adequate corrosion protection, a minimum of 30%
2010 Caterpillar
Page 39
and maximum of 50% concentration may be used. The antifreeze agent can
consist of either ethylene or propylene glycol.
It is recommended to use Caterpillar distributed antifreeze/corrosion
inhibitors (NGEC).
Recommended Antifreeze and Service Life
Antifreeze
Service Lifetime*
Caterpillar NGEC
Three Years
Caterpillar DEAC
Three Years
ASTM D6210
Two Years
ASTM D4985
One Year
Caterpillar SCA and Water

Commercial SCA and Water
Two Years
One Year
* Service Lifetime is also limited by operation hours. Please refer to the engine
Maintenance Schedule.
Flex Connection Installation
All flexible connections are in the Caterpillar standard scope of supply.
Check the packaging of the rubber compensators for damage. Damaged

compensators must never be released for installation.
Check the envisaged installation gap. The mating flange must be installed
in true alignment.
Refer to the engine manual for the maximum allowable misalignment.
The maximum deviation within the installation gap in relation to the

compensator is minus the corresponding expansion specifications.
Refer to the manufacturers values for the maximum lateral deviation of

the flange.
Example:
For specific allowed
deviation, please refer to the
installation drawings and
manual.
Page 40
2010 Caterpillar
Air Consumption of the Instrumentation
During normal operation, the steady state air consumption of each control
valve is 0.6 Nm/hr (0.35 scfm). The skid has 4 valves; therefore total
steady state consumption per skid will be 2.4 Nm/hr (1.4 scfm).
Normal operation means that the valves are only making small adjustments
at a time, and are not trying to quickly adjust for large variations.
In a worst case scenario, as seen during engine warm-up / loading cycle,
you could have all four valves making large and quick adjustments
simultaneously; in this case it would be possible for each valve to require
13.6 Nm/hr (8.0 scfm), and since the skid has four valves, there could be a
maximum consumption of 54.4 Nm/hr (32 scfm) per skid. The duration of
this maximum consumption will vary since it is dependent on the start-up
and loading cycle of the engine.
For further technical information please refer to auxiliary skid information
from your Caterpillar representative.
Starting Gas/Air System

For compression applications, an engine mounted twin starter unit is part
of the standard equipment; the media can be gas TD112 or air TD121.
The Gas inlet pipe system should be sized to 3 to minimize restrictions

and pressure reduction.
Starter air/gas exhaust piping should be designed to 4 to avoid any
exhaust restriction. Backpressure in the starter exhaust system might
prevent correct starter operation.
If the starter exhaust is combined with other engines starters, a check
valve in the exhaust pipe must limit the backpressure to 34.4 kPa (5 psi).
2010 Caterpillar
Page 41
Gas Starters T112-V

Gas starters, such as the T112-V, are designed to operate at 10 bar (150
psi).
Air Starters T121-V

Air starters, such as the T121-V, are designed to operate at 10 bar (150
psi).
For gas/air consumption, please consider a double starter system.

Page 42
2010 Caterpillar
System Description
Metric (English)
G16CM34
Gas Starter (TD112) Consumption

Nm3 (scfm)
2x 6508 (2x 3828)
Air Starter (TD121) Consumption

Nm3 (scfm)
2x 5460 (2x 3212)
Lower pressure starters, at 6 bar (90 psi) operation pressure, are available
upon request.
The required starting air/gas volume will depends on total cranking time of
the engine. The normal start cycle includes a 20 second purge time before
fuel is allowed to enter the engine. This purges the exhaust system and
reduces the risk of exhaust explosions.
If air will be used for engine start, compressor and air receivers should be
sized accordingly to the air consumption and possible/required start
attempts. Six start attempts are recommended. Two independent receivers
with 50% of the total required air capacity are recommended.
For load acceptance within the starting sequence, please see engineloading strategy within this document. Flexible connections must be installed
for starter inlet piping and starter exhaust piping. The flexible connections
are in the Caterpillar standard scope of supply.
Avoid any particle or dirt entering the starter, as this can reduce starter life
and/or failure can occur.
System Description
Metric (English)
Supply Pressure
bar (psi)
Starting media
Minimum media temperature
C (F)
Maximum media temperature
C (F)
G16CM34
10 (150)
Air, Natural Gas, Pipeline Gas
- 40 (-40)
79 (174.2)
Oil viscosity and temperature are significant factors in the amount of torque needed to
crank the engine.
2010 Caterpillar
Page 43
Engine Barring Device
The GCM34 engines are equipped with a remotely controlled barring device
to turn the engine slowly for maintenance purposes. The turning device
requires 10 bar (150 psi) clean, dry compressed air.
Danger! Do not use natural gas to operate the engine baring device.
Ensure adequate piping sizing to guarantee required air flow. The air supply
of the barring device also includes an inline lubricating device (oiler) to
improve performance of the gear. The oil reservoir must be filled with
lubricating oil when the barring device is used. Engine lube oil type can be
used for this application.
Air hoses for the remote control are in the Caterpillar standard scope of
supply.
System Description
Metric (English)
G16CM34
Supply Pressure, Minimum

bar (psi)
6.2 (90)
Supply Pressure, Maximum

bar (psi)
10 (150)
Starting Media
Maximum Media Temperature
C (F)
Dry Air
55 (131)
Oil viscosity and temperature are significant factors in the amount of torque needed to
turn the engine.
Page 44
2010 Caterpillar
Engine Electric
Engine Speed Governing
The engine speed-governing feature is used to control (govern) the engine
speed to the desired engine speed. Speed governing is accomplished by
varying the fuel delivered to the engine. It uses a closed-loop PID algorithm
to determine the necessary input energy-flow (the amount of energy supplied
to the engine by the SOGAVs) to meet the current engine speed and load
requirements.
Fuel Flow Calculation
The fuel-flow calculation feature calculates the fuel command, and both
mass and volume of the fuel-flow. The fuel-flow command is used to
calculate the SOGAV duration, while the other fuel-flow values are used to
control the air-fuel ratio and limit the engine power and torque output. The
fuel-flow calculations can operate in either open- loop or closed-loop mode.
Open-Loop Fuel-Flow Calculation
In open loop mode, the fuel command and fuel-flow values are calculated
directly from the governor output, with the assumption that the fuel-flow
commanded is equal to the actual fuel-flow.
Closed-Loop Fuel-Flow Calculation
When the engine control system is operating in closed-loop air-fuel mode,
feedback of the combustion burn-times is used to determine the correction
factor. This corrects the errors in the fuel-flow calculation resulting from
changes in the fuel constituents or any other error, which may have lead to
incorrect fuel-flow values. That is important because fuel-flow errors will
result in errors in the actual air-fuel ratio and can adversely affect engine
performance.
Engine Control and Monitoring

Engine Control Module (ECM)
The ECM is an ADEM III (Advanced Digital Engine Management) based
control platform mounted on the engine frame and used to operate a GCM34
engine. This system contains all components and functions needed to
optimally run the engine. It consists of following systems:
Engine governing system
Ignition control system
Air/Fuel Ratio control system
Engine protection and monitoring system
Detonation protection
2010 Caterpillar
Page 45
Parameters Management
Caterpillar Electronic Technician (Cat ET)
The Cat ET allows operators to configure the PL1000E parameter, view
engine parameters and diagnostic codes for troubleshooting through your
laptop computer. Contact your Caterpillar local dealer for more information
about this communication tool.
PL1000E
Communication between the ADEMIII system and a remote control system
is possible with the PL1000E; it translates the system tags from CDL to
Modbus. The PL1000E resides in the LCP.
SCADA Interface
All data in the engine PLC are available for the SCADA system. It is
recommended to use the metric or English scaled tags as listed in the control
system specification manual. The base tags and data flow diagram are also
included in this manual.
Page 46
2010 Caterpillar
Local Control Panel
The system includes a PLC based Local Control Panel (LCP) and a blank
sub panel for the compressor control system. Purchasing and installation of
compressor control system components is not included in the standard LCP
but available as an option. The LCP is a two door NEMA 4 72 x 72 x 12
front access, stainless steel enclosure with sub panels for the engine and the
compressor control system. The enclosure is equipped with 12 legs and an
operator interface for displaying operating parameters and system messages.
The standard system requires a 24 V DC auxiliary power source. A 120 V
AC version is available as an option.
The following will be in the scope of control of the engine PLC:
All devices on the auxiliary skid
All factory install devices mounted on the engine
All ADEM III interfacing (including parameters over the Caterpillar Data
Link)
All device on the GRU
Inlet air filter monitoring
Crankcase ventilation unit
Jacket water cooling fans (quantity of fans varies with location)
Network Communication
The GCM34 LCP uses an Allen-Bradley Logix platforms, which provides
single integrated control architecture for discrete process, and safety control.
The Logix platforms provide a common control engine, programming
software environment, and communication support across multiple hardware
platforms. These controllers offer the benefits of the Common Industrial
Protocol (CIP) to communicate via EtherNet, ControlNet, and Modbus
networks.
Ethernet
Engine control will require the use of six following IP addresses:
ControlLogix Ethernet bridge (1756-ENBT) card
PanelView Plus HMI
PL1000E
MVI56-MNET I/P
MVI56-ADMNET (only required when remote monitoring is installed)
Laptop (or Router if remote monitoring is installed)
If the PLC is to be on the customers network, then it will be the

responsibility of the customer to assign the IP addresses. If the unit is not
2010 Caterpillar
Page 47
connected to a customer network, then see description in the technical

specification.
Modbus
Data from the engine control modules (ECM) will be read using the Prosoft
MVI56-MNET Modbus module for the ControlLogix. The MNET module
resides in the ControlLogix Chassis and communicates via Modbus to the
Caterpillar PL1000E communications gateway. The PL1000E communicates
with the Caterpillar ECMs using the Cat Data Link (CDL). PL1000E data
address will be Node 1. The PL1000E actually uses two modbus addresses,
one address for the web server data and one address for the data that is
produced over the modbus link. Node 1 refers to the data that is produced
over the modbus link. For configuration purposes, refer to the specification
manual.
ControlNet
All inputs and outputs of the auxiliary skid and MCC will be read over a
ControlNet network which consists of following components:
ControlLogix ControlNet bridge (1756-CNB) card will be Node 1
Auxiliary Skid Flex I/O adapter ControlNet (1794-ACN15) will be Node

4
MCC mounted I/O will be Node 5 (provided by customer)
Wiring
For operation, the customer shall complete the wiring system. The engine
and its operating components shall be hardwired to the power supplied. All
PLC digital and analog I/Os shall be wired as described below. A wiring
mistake will cause the system to fail.
Page 48
2010 Caterpillar
2010 Caterpillar
Page 49
Cable Plan Diagram (Example Only)
Page 50
2010 Caterpillar
Cable Plan Description (Example Only)

Engine mounted Terminal Box to the LCP
Refer to the Cable Plan Diagram. The Engine Terminal Box includes 6
DIN89280-3-24 and 1 DIN89280-3-18 threads for safety connection of 7
cables. The implementation of the wiring connection between the Engine
Mounted Terminal Box and the Local Control Panel (LCP) is not within the
Caterpillar scope of supply. Therefore, the customer shall choose the correct
type of cable for their connections, the wires in each cable, and the DIN
thread through which the cable will be connected according to our submitted
technical documents. The following implementation is only an example and
shall be used only for information purposes.
Cable 1: Engine Power
o Minimum of 8 stranded copper conductors
o Minimum of 10awg (5,27mm), not to exceed 150ft
o Minimum 600V
o TFFN or better
Cable 2: Digital I/O for Engine Terminal Box
o Minimum 26 stranded copper conductors
o Minimum 16awg (1,31 mm)
o Minimum 300V
Cable 3: Cat Data Link
o Belden 8719 or equivalent (Cat part number 123-2376)
Cable 4: CAN Data Link
o Northwire Inc. FJ1939182-005 or equivalent (Cat part number
153-2707)
Cable 5: Thermocouples
o K type thermocouple cable
o Minimum of 2 pairs
Cable 6: Analog Signal Triads
o Minimum of 5 stranded copper triads (3 wires, shielded)
o Minimum of 18awg (0, 82 mm)
o Minimum 300V
Cable 7: Analog Signal Twisted Pair
o Minimum of 3 stranded copper twisted pairs (2 wires, shielded)
o Minimum 300V
Note: The 7 DIN threads are standard and could be extended from
Caterpillar, if required. The numbers of spare wires are up to customer.
2010 Caterpillar
Page 51
Local Control Panel to Field Devices

Cable 1: EStop
o Minimum 300V
Cable 2: Low Oil Level
o Minimum 300V
Cable 3: Gas Fuel Filter (Option)
Cable 4a: Fan Vibration Analog Signal Twisted Pair (Option)
o Minimum 300V
Cable 4b: Fan Vibration Analog Signal Twisted Pair (Option)
o Minimum 300V
Note: Assuming 2 jacket water cooling fans
Cable 5: Engine Vibration Analog Signal Twisted Pair (Option)
o Minimum 300V
Cable 6: Engine Drive End Vibration Digital Input (Option)
Cable 7: Engine Non Drive End Vibration Digital Input (Option)
Note: If the packager installs a junction box, then the number of cables and
conductors will vary depending on which signals are routed into the junction
box.
Page 52
2010 Caterpillar
Local Control Panel to Auxiliary Skid

Cable 1: DC Power
o Minimum of 2 stranded copper conductors
o Minimum of 12awg (3,31mm), not to exceed 200ft
o Minimum 600V
o TFFN or better
Cable 2: ControlNet
o RG-6 Quad Shield Coax (Belden 3092A or equivalent
Local Control Panel to Fuel Skid
Cable 1: Digital Outputs
o Minimum 300V
o Minimum 300V
Local Control Panel to Air Filters
Cable 1: Analog Signal Triads
o Minimum of 2 stranded copper triads (3 wires, shielded)
o Minimum 300V
o Minimum 300V
Note: Assuming 2 air filters
Local Control Panel to MCC
Cable 1: ControlNet
o RG-6 Quad Shield Coax (Belden 3092A or equivalent
2010 Caterpillar
Page 53
List of Wires for a GCM34 Application

Abbreviations:
EMTB = Engine Mounted Terminal Box
LCP = Local Control Panel
MCC = Motor Control Centre
Aux Skid = Combined Module Auxiliary Skid
Field = Field Mounted Device
Fuel Skid = Fuel Skid Terminal Box
Air Filters = Air Filters Mounted Device
LCP - Comp = Compressor sub-plate mounted in Local Control Panel
GCM34 to LCP
From
To
Size
AWG
Wire Details
LCP
X7-1
EMTB
X7-1
#10
600V, TFFN
LCP
X7-1
EMTB
X7-1
#10
600V, TFFN
LCP
X7-2
EMTB
X7-2
#10
600V, TFFN
LCP
X7-2
EMTB
X7-2
#10
600V, TFFN
LCP
X7-7
EMTB
X7-7
#10
600V, TFFN
LCP
X7-7
EMTB
X7-7
#10
600V, TFFN
LCP
X7-8
EMTB
X7-8
#10
600V, TFFN
LCP
X7-8
EMTB
X7-8
#10
600V, TFFN
LCP
LCP
X5-26
X5-25
EMTB
EMTB
X5-26
X5-25
#16
#16
300V,TFFN
300V,TFFN
LCP
X5-24
EMTB
X5-24
#16
300V,TFFN
LCP
LCP
LCP
LCP
LCP
X5-1
X5-2
X5-11
X5-18
X5-19
EMTB
EMTB
EMTB
EMTB
EMTB
X5-1
X5-2
X5-11
X5-18
X5-19
#16
#16
#16
#16
#16
300V,TFFN
300V,TFFN
300V,TFFN
300V,TFFN
300V,TFFN
Page 54
Description
Engine 24VDC power
wire
Engine 24VDC power
wire
Engine 24VDC power
wire
Engine 24VDC power
wire
Engine 24VDC power
wire
Engine 24VDC power
wire
Engine 24VDC power
wire
Engine 24VDC power
wire
Start Solenoid Relay +
Start Solenoid Relay Turning Gear Engaged
Switch ECM Estop +
ECM Estop Off / Reset
Run Relay
Crank Terminate Relay
2010 Caterpillar
LCP
LCP
LCP
LCP
X5-20
X5-21
X5-28
FU407
EMTB
EMTB
EMTB
EMTB
X5-20
X5-21
X5-28
X5-27
Size
AWG
#16
#16
#16
#16
LCP
X5-17
EMTB
X5-17
#16
300V,TFFN
LCP
FU406
EMTB
X5-16
#16
300V,TFFN
LCP
X5-15
EMTB
X5-15
#16
300V,TFFN
LCP
FU405
EMTB
X5-14
#16
300V,TFFN
LCP
X5-13
EMTB
X5-13
#16
300V,TFFN
LCP
FU404
EMTB
X5-12
#16
300V,TFFN
LCP
LCP
LCP
FU-604
FU-605
FU-606
EMTB
EMTB
EMTB
X5-8
X5-7
X5-9
#16
#16
#16
300V,TFFN
300V,TFFN
300V,TFFN
LCP
FU-607
EMTB
X5-5
#16
300V,TFFN
LCP
FU-608
EMTB
X5-4
#16
300V,TFFN
LCP
FU-609
EMTB
X5-6
#16
300V,TFFN
LCP
FU-610
EMTB
X5-10
#16
300V,TFFN
LCP
FU-611
EMTB
X5-3
#16
300V,TFFN
LCP
X5-31
EMTB
X5-31
#18
From
To
LCP
X5-32
EMTB
X5-32
#18
LCP
X5-33
EMTB
X5-33
#18
LCP
X13-7
EMTB
X13-7
#18
LCP
X13-9
EMTB
X13-9
#18
2010 Caterpillar
Wire Details
300V,TFFN
300V,TFFN
300V,TFFN
300V,TFFN
Description
Engine Failure Relay
Engine Alarm Relay
ECM Power Derate ECM Power Derate +
ECM Prelube command
ECM Prelube command
+
ECM Gas Shutoff Valve
Command ECM Gas Shutoff Valve
Command +
ECM Start Solenoid
Command ECM Start Solenoid
Command +
Start Command to ECM
Stop Command to ECM
Auto Command to ECM
Normal Stop Command
to ECM
Driven Equipment Ready
Command to ECM
Idle/Rated Command to
ECM
Grid On/Off Command to
ECM
Timing Command to
ECM
Engine Speed MPU -
Shielded,
Stranded,
Copper Triad
Engine Speed MPU

Signal
Engine Speed MPU +
J1939 cable CAT# 153-2707 J1939 + (CAN High

or Northwire
Inc. FJ1939182- J1939 - (CAN Low))
005
Page 55
From
Size
AWG
To
Wire Details
Shielded,
Stranded,
Copper Twisted
Pair (Cat part #
123-2376 or
Belden 8719)
Shielded,
Stranded,
Copper Twisted
Pair
Shielded,
Stranded,
Copper Twisted
Pair
Shielded,
Stranded,
Copper Triad
Shielded,
Stranded,
Copper Triad
Shielded,
Stranded,
Copper Triad
Shielded,
Stranded,
Copper Triad
K - Type
Thermocouple
cable
K - Type
Thermocouple
cable
Shielded,
Stranded,
Copper Twisted
Pair
LCP
X13-5
EMTB
X13-5
#16
LCP
X13-3
EMTB
X13-3
#16
LCP
X5.1-1
EMTB
X5.1-1
#18
LCP
X5.1-2
EMTB
X5.1-2
#18
LCP
X5.1-3
EMTB
X5.1-3
#18
LCP
X5.1-4
EMTB
X5.1-4
#18
LCP
LCP
LCP
LCP
LCP
LCP
LCP
LCP
LCP
LCP
LCP
LCP
FU-706
X5.1-15
X5.1-14
X5.1-11
X5.1-12
X5.1-13
X5.1-7
X5.1-8
X5.1-9
X5.1-21
X5.1-22
X5.1-23
EMTB
EMTB
EMTB
EMTB
EMTB
EMTB
EMTB
EMTB
EMTB
EMTB
EMTB
EMTB
X5.1-16
X5.1-15
X5.1-14
X5.1-11
X5.1-12
X5.1-13
X5.1-7
X5.1-8
X5.1-9
X5.1-21
X5.1-22
X5.1-23
#18
#18
#18
#18
#18
#18
#18
#18
#18
#18
#18
#18
LCP
X5.1-17
EMTB
X5.1-17
#18
LCP
X5.1-18
EMTB
X5.1-18
#18
LCP
X5.1-19
EMTB
X5.1-19
#18
LCP
X5.1-20
EMTB
X5.1-20
#18
LCP
X5.1-5
EMTB
X5.1-5
#18
LCP
X5.1-6
EMTB
X5.1-6
#18
EMTB X5.1-6
EMTB
X7-8
#18
300V,TFFN
Field
#16
300V,TFFN
LCP
Page 56
FU-137 Common
Description
CDL - (not to exceed
100ft)
CDL + (not to exceed
100ft)
Prechamber Gas
Pressure Regulator
Command from ECM
Main Chamber Gas
Pressure Regulator
Command from ECM
Charge Air DP +
Charge Air DP Signal
Charge Air DP HT Water Inlet
Temperature (2201)
Intake Air Manifold
Temperature
Temperature
Compensation
A Bank Air Temperature
before Charge Air
Cooler (7309A)
B Bank Air Temperature
before Charge Air
Cooler (7309A)
Engine Speed
Reference
Jumper Speed Ref (-) to
DC(-) in EMTB
Station E-Stop dry
contact 24VDC+
2010 Caterpillar
From
LCP
TB-137
LCP
TB-415
LCP
Size
AWG
Wire Details
Field
#16
300V,TFFN
Field
#16
300V,TFFN
Field
#16
300V,TFFN
Size
AWG
Wire Details
#12
600V, TFFN
#12
600V, TFFN
Size
AWG
Wire Details
TB-5
#16
300V,TFFN
TB-6
#16
300V,TFFN
TB-1
#16
300V,TFFN
TB-2
#16
300V,TFFN
TB-7
#16
300V,TFFN
TB-8
#16
300V,TFFN
TB-3
#16
300V,TFFN
TB-4
#16
300V,TFFN
To
N.C.
N.C. /
N.O.
FU-415 Common
Description
Station E-Stop dry
contact
Low Oil Level Input (0 =
Shutdown)
Low Oil Level Switch +
Auxiliary Skid to LCP

From
LCP
LCP
To
FU-116 Aux Skid 24VDC(+)

TB-2
Aux Skid 24VDC(-)
Description
Aux Skid 24vdc power
wire
Aux Skid 24vdc power
wire
Fuel Skid to LCP

From
LCP
TB-126
LCP
TB-2
LCP
TB-127
LCP
TB-2
LCP
TB-128
LCP
TB-2
LCP
TB-129
LCP
TB-2
To
Fuel
Skid
Fuel
Skid
Fuel
Skid
Fuel
Skid
Fuel
Skid
Fuel
Skid
Fuel
Skid
Fuel
Skid
LCP
TB-700
Fuel
Skid
TB-26
#18
LCP
TB-701
Fuel
Skid
TB-25
#18
2010 Caterpillar
Description
Main Chamber Fuel Vent
Valve +
Main Chamber Fuel Vent
Valve Main Chamber Fuel
Block Valve +
Main Chamber Fuel
Block Valve PreChamber Fuel Vent
Valve +
PreChamber Fuel Vent
Valve PreChamber Fuel Block
Valve +
PreChamber Fuel Block
Valve -
Shielded,
Prechamber Gas
Stranded,
Pressure Regulator
Copper Twisted
Command to Fuel Skid
Pair
Page 57
From
LCP
Size
AWG
To
Fuel
Skid
TB-703
TB-24
#18
Wire Details
Description
Shielded,
Main Chamber Gas
Stranded,
Pressure Regulator
Copper Twisted
Command to Fuel Skid
Pair
Air Filter to LCP

From
Size
AWG
To
LCP
FU-713 Air Filter
(+)
#18
LCP
TB-714 Air Filter
(-)
#18
LCP
FU-715 Air Filter
(+)
#18
LCP
TB-716 Air Filter
(-)
#18
LCP
LCP
LCP
LCP
LCP
LCP
TB-825
TB-826
TB-827
TB-831
TB-832
TB-833
Signal
Common
Common
Signal
Common
Common
#18
#18
#18
#18
#18
#18
Air Filter
Air Filter
Air Filter
Air Filter
Air Filter
Air Filter
Wire Details
Shielded,
Stranded,
Copper Twisted
Pair
Shielded,
Stranded,
Copper Twisted
Pair
Shielded,
Stranded,
Copper Triad
Shielded,
Stranded,
Copper Triad
Description
A Bank / Single Air Filter
DP
B Bank Air Filter DP

(Option)
A Bank / Single Air Filter
Temperature
B Bank Air Filter
Temperature (Option)
Compressor to LCP
From
LCP
FU-146
To
LCP - Comp
Size
Description
AWG
#16
Hardwired Shutdown by Compressor +
LCP
(0 = Shutdown)
LCP
Hardwired Shutdown by Compressor -
TB-146
LCP - Comp
#16
LCP
(0 = Shutdown)
LCP
FU-133
LCP - Comp
#14
Compressor Panel 24VDC+
LCP
TB-2
LCP - Comp
#14
Compressor Panel 24VDC-
Page 58
2010 Caterpillar
Cooling Fans to LCP

From
Size
Description
AWG
Water Cooling Fan #1 Vibration +
#16
(Option)
Water Cooling Fan #1 Vibration #16
(Option)
#16
(Option)
(Option)
#16
(Option)
(Option)
To
LCP
FU-316
Field
LCP
TB-316
Field
LCP
FU-317
Field
LCP
TB-317
Field
LCP
FU-318
Field
LCP
TB-318
Field
Fuel Gas Filter Value to LCP

From
To
LCP
FU-416
(+)
Field
LCP
TB-416
(-)
Field
Size
Description
AWG
Fuel Gas Filter High Level +
#16
(Option)
Fuel Gas Filter High Level Input
#16
(Option)
Engine Vibration Transmitter to LCP

Size
From
To
AWG
Wire Details
LCP
FU-417
(+)
Field
#16
300V,TFFN
LCP
TB-417
(-)
Field
#16
300V,TFFN
LCP
FU-418
(+)
Field
#16
300V,TFFN
LCP
TB-418
(-)
Field
#16
300V,TFFN
2010 Caterpillar
Description
Engine Drive End High
Vibration +
(Option)
Engine Drive End High
Vibration Input
(Option)
Engine Non-Drive End
High Vibration +
(Option)
Engine Non-Drive End
High Vibration Input
(Option)
Page 59
From
Size
AWG
To
LCP
FU-718
(+)
Field
#18
LCP
TB-719
(-)
Field
#18
Wire Details
Description
Shielded,
Engine Vibration
Stranded,
Transmitter
Copper Twisted
(Option)
Pair
ControlNet to LCP
From
Size
AWG
To
LCP
T-Tap
T-Tap Aux Skid
#18
LCP
T-Tap
T-Tap
#18
MCC
Wire Details
Description
RG-6 Quad
Shield Coax
(Belden 3092A
or equivalent)
RG-6 Quad
Shield Coax
(Belden 3092A
or equivalent)
ControlNet (note that

CNET can be converted
to Fiber but hardware is
not included for that)
ControlNet (note that
CNET can be converted
to Fiber but hardware is
not included for that)
Notes:
Power wiring for the LCP will be sized by the customer depending on
distance from source and type of voltage. The wire size should be
capable of the following depending on voltage:
o 120 AC Voltage Option: Minimum 30 Amps w/ 600v insulation
o 24 DC Voltage Option: Minimum 70 Amps w/ 600v insulation.
All ControlNet cabling shall be RG-6 quad shield
Warning
Do not disconnect or connect equipment electrically unless the area is

known to be free of explosive gases
All field wiring must enter and exit enclosure through metallic conduit
and have sealed fittings not more than 457 mm (18 inches) from
enclosure
All engine power wiring shall be stranded cooper, 600V THAN, #12
AWG minimum
All power wiring from disconnect to distribution block shall be #6

AWG
All ground wiring shall be #14 AWG minimum, typically one size larger
than power wiring
Page 60
2010 Caterpillar
PLC System
A GCM34 operation is a fully automatic application using the PLCProcessor to control the engine according to a setting point. Therefore the
PLC allows following operation:
GCM 34 Interface / Display
Monitoring
Start / Stop
Engine Derating
Alarm / Shutdown Log
Interface to PLC to Set Parameters
Start Preparations / Stop Procedures
Auxiliaries Control (pumps, gas leakage test, exhaust ventilation, etc.)
Compressor Protection
Speed / Load Control
Engine Derate
The engine processor will produce a parameter. Under normal operating

condition, this parameter will contain a value of 100%. In the event of a
derate condition, the value in this tag will start decreasing. The derate
function will be implemented in the PLC. A map of the gas compression
application derate is included in the mechanical part of this guide.
Switches & Lamps

Summary Alarm Lamp (SAL)
The Summary Alarm Lamp will flash when a new alarm becomes active.
Once the alarm is acknowledged, the lamp will stop flashing and turn solid
on. The lamp will turn off when all alarms have been acknowledged and are
no longer present.
Summary Shutdown Lamp (SSL)
The Summary Shutdown Lamp will flash when a new shutdown becomes
active. Once the shutdown is acknowledged the lamp will stop flashing and
turn solid on. The lamp will turn off when the shutdowns are reset.
Engine Running Lamp (ERL)
The Engine Running Lamp is illuminated anytime the engine is running.
Reset Push Button (RPB)
The Reset Push Button has two different actions depending on the status
of the engine. If the engine is running, the RPB will clear all the PLC
generated alarms and sensor failures (not shutdowns). If the engine is not
running, the RPB will clear all the PLC generated alarms, sensor failures, and
2010 Caterpillar
Page 61
shutdowns. If an engine shutdown was triggered by the ADEM ECM, the

button will reset all ECMs, including the PL1000E.
Note: Removing power from Pin 70 on all ECMs resets the ECMs. The RPB
will remove power for 7 seconds. The ADEM will only reset if all
communications on the data link are stopped. This means that the Cat
Electronic Technician must be disconnected for the ADEM to reset.
Engine Control Switch (ECS)
The Engine Control Switch is a two position keyed switch used to
stop/reset and start the engine. Removing the key will lock out the engine
from use.
The two positions are listed below:
OFF/RESET This is the only position in which the key can be removed
from the switch. When the key switch is in this position, the following
actions occur:
The engine cannot be started in manual or auto
All alarms, shutdowns, and signal failures will be reset
Power all ECM Pin 70s will be removed which will reset the ADEM
faults
The compressor can start in Local Auto RUN
In order to run the engine in Auto or Manual the ECS must be in the
Run position
The compressor can stop in Local Auto
Emergency Stop
The Emergency Stop push button will stop the engine and all auxiliary
motors. All normal stop sequencing will be bypassed.
Control Concept between the Engine and Compressor
Caterpillar has standardized on a control concept that segregates the

engine control from the compressor control but keeps the components in the
same local cabinet. Caterpillar will provide the engine protection and control.
An external manufacturer will provide the compressor protection and control.
Independent control program processors for engine control programming and
compressor control programming are located in one panel. Data will be
shared across the panel backplane to allow for easy integration between the
two systems. The engine and compressor control systems will each have
their own segregated I/O control networks. The panel containing the
processors will also contain I/O modules used for engine control. In the
shared control cabinet, there will be room for at least two additional 13-slot
panels that can be used for compressor I/O.
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2010 Caterpillar
Engine Control Concept
Shared
Ethernet
Compressor
I/O Network
Engine I/O
Compressor
Processor
Engine
ControlNet
Engine
Processor
Compressor to Engine Interface

(Produced and Consumed Tags)
Engine I/O (Slots 8-12)
Shared Ethernet
Engine Field I/O
Compressor I/O
HMI Network
The Compressor I/O can be either field I/O

or mounted in the shared local cainet
Grounding
Connecting the electrical system to the earth helps to limit the voltage
potential between the equipment and earth. The grounding technology used
for a GCM34 application depends of each installation areas and the power
supplied. The grounding technology on the site is not within the Caterpillar
scope of supply. We recommend therefore providing an adequate grounding
system according to your engine site.
In the following chapter, this guide will only provide some grounding
recommendations for a better understanding of how to connect each
electrical system to the ground web. Caterpillar considers that the equipment
grounding and bonding are already completed.
Grounding Electrode System
A grounding electrode provides a connection between the electrical system
and earth. Adequate grounding electrodes should be chosen according to
your site specification and the NEC [250-50]. All the grounding electrodes at
the site must all be bonded together to form the grounding electrode system
[250-50]. Material and size of a grounding electrode are illustrated in NEC
[250-52]. Because of the largest engine site, Caterpillar recommends the use
2010 Caterpillar
Page 63
of a ground ring. This will allow the grounding electrode conductors to be

short.
Grounding Electrode Conductors
The conductors that connect from the service equipment to the grounding
electrode are referred to as grounding electrode conductors. This conductor
must electrically connect to the incoming neutral service conductor. In the
best case, conductors shall not be longer than 6ft and the grounding system
resistance to ground shall not exceed 5 ohms.
Sizes and Materials of Alternating Current Grounding Electrode Conductor
The grounding electrode conductor helps to reference the service
equipment to earth, and therefore its size is based upon the size of the
service entrance conductors entering the installation. While several factors
contribute to the rating of the service (conductor size, equipment rating, and
main breaker) the only factor to consider in sizing the grounding electrode
conductor is the service entrance conductor. NEC 250-66 shows the
minimum sizes of grounding electrode conductors.
Sizes and Materials of Direct Current Grounding Electrode Conductors
The size of the grounding electrode conductors for a DC system is
illustrated in NEC 250.166(A-E). If connected to a ground ring, this
conductor shall not be required to be lager than the one used for the ground
ring.
Engine Block
The grounding screw (M16) at each corner of the engines block bottom
shall be used to connect the engine to the installed grounding system.
Caterpillar recommends the use of an appropriate copper cable according to
the NEC recommendations. Some previous installations of Caterpillar engines
are using a #1 AWG copper cable to connect one of the engine ground lugs
to the grounding electrode system at the site. For an installation such as a
generator set, the both grounding lugs shall be connected to the grounding
electrode system.
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2010 Caterpillar
Fuel Skid
Following pictures are
illustrating the way to ground
the fuel skid system. In order
to connect the unit with the
global grounding system, use
the earth bar. At the earth bar
are some free connections for
different sizes of cables. Only
qualified personnel may use
the design. Calculation and
implementation of the
grounding conductor must be
done first. The local rules,
regulations and laws (NEC 250.66) must be observed. There will be a
minimum diameter of 16mm (#7 AWG) copper cable recommended. All
connection elements must be a permanent, reliable electrical connection by
welding, presses, clamps or other mechanical fasteners.
Auxiliary Skid
The skid will include 4
grounding lugs, one at each
corner of the auxiliary skid, to
keep the cable as short as
possible. Each 460 VAC
motor case will be wired with
a #10 AWG grounding wire to
a close proximity grounding
boss. To make provisions for
a complete system ground (to
earth), the customer must run
appropriate wiring from a
ground (earth reference) to the skid boss(s) as shown. Caterpillar
recommends using grounding cable with a minimum diameter of 35mm or
(#2 AWG) for this connection.
2010 Caterpillar
Page 65
Air Filter
The air filter grounding
point is shown. This
grounding screw must be
connected to the grounding
web of the grounding
electrode system. Caterpillar
recommends using a cable
with a section of 25mm2 (#
4 AWG aluminum).
Local Control Panel

The green grounding
connector (#6 AWG) copper
shall be connected with the
local control panel and to
the ground bus. Use at
minimum #6 AWG copper to
connect the ground bus to
the grounding-electrode
system. The National
Electrical Code (Article 250)
specifies size and safety
requirements for the
grounding-electrode
conductor.
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2010 Caterpillar
Crankcase Ventilation
The crankcase
ventilation grounding is
in the terminal box as
shown.
Attach a #12 AWG
wire at the grounding
screw inside of the
electrical junction box
of the motor. This wire
should be routed to any
good earth ground
terminal within your
electrical network.
GCM34 Gas Engine Factory Acceptance Test (FAT)

Caterpillar GCM34 gas engines are tested in the Rostock, Germany facility
where they are assembled.
Each GCM34 engine will be tested according to a pre-determined program,
to deliver all parameters within the scope of engine operation.
A delegation from the customer may attend the test and eyewitness the
test run. To make needed arrangements please contact your Caterpillar
representative.
Before the official FAT can start, the engine must perform an installation
and check run for at least 7 hours in various load steps while the engine is
being adjusted and tested.
The acceptance test run is carried out on the test bed with customary
equipment and the gas control unit of the test bed, using natural gas and
under the respective ambient conditions of the test bed. During this test the
engine will be loaded with power in compliance with the contractual values.
In case of deviations from the contractual ambient conditions the gas
consumption will be converted to standard reference conditions.
During the acceptance test the engine will be run at the following load
steps. After reaching a steady state condition of pressures and temperatures,
these will be recorded and registered as mean values acc. to the form sheet
of the gas engine acceptance test certificate.
2010 Caterpillar
Page 67
Standard FAT Measuring Points (Test Cycle)

At Nominal Speed:
1. 100% Torque
2. 75% Torque
3. 50% Torque
At Maximum Turndown:
4. 100% Torque
5. 50% Torque
* Extended testing can be offered at customers request.
In addition, the following functional tests will be carried out:
Engine safety shut downs
Start/stop via central engine control
Starting trials up to a minimum air pressure of 10 bar
Crank web deflection measurement (cold/warm)
After the acceptance test, the main running gear, camshaft drive and
timing gear train will be inspected through the opened access covers.
Installation Recommendations
Various mounting options are available to the customer; all of which
present benefits as well as difficulties. It is the customers responsibility to
provide correct engine mounting, as well as all foundation design, calculation
and construction.
It is required to follow the Caterpillar alignment recommendations.
The alignment and crankshaft deflection must be checked once a year and
corrections made if necessary. This prevents damage to coupling and driven
equipment due to misalignment.
Please consider all information that is required for proper mounting when
designing the engine foundation.
For further information about engine mounting, please refer to your
Caterpillar representative.
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2010 Caterpillar
Engine Lifting
For the purpose of transporting, the engine is equipped with a lifting

device, which shall remain the property of Caterpillar. It must be returned in
a useable condition freight prepaid.
System Description
Metric (English)
Maximum Lifting Speed
m/min (ft/min)
Engine Dry Weight
kg (lbs)
2010 Caterpillar
G16CM34
5 (16)
82000 (180779)
Page 69
Engine Mounting
Engine Block Foundation
The following information is relevant to foundation design and constitutes
general information to be used as a guideline only. The engine foundation is
subjected to both static and dynamic loads.
The customer is solely responsible for proper design of the engine mounting.
The following shows the quantity and type of mounting bolts for a
G16CM34 installation.
Number of
Bolt Holes
Jacking Bolts
Foundation Bolts
44
Fitted Bolts
4
For details, refer to engine installation drawing 229000 M -EID -209,

Foundation on Compressor Skid (steel base frame foundation).
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2010 Caterpillar
Tightening Forces
Tightening Force M33
Minimum Tightening Torque M33
Through
Foundation Bolts
Newton
Fitted Bolts
Newton
Through
Foundation Bolts
Newton
110 000
110 000
650*
Fitted Bolts
Newton
650*
* All 44 foundation bolts used.
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Page 71
Thermal Expansion
From engine startup to engine temperature at full load, the engine will
undergo some thermal growth. The engine alignment and the engine
mounting must consider this normal growth behavior.
GCM34 Thermal Expansion
Thermal Grow th of crankshaft above engine foot at

operating temperature [mm ]
0.6
0.55
0.5
0.45
0.4
0.35
0.3
0.25
0.2
0.15
0.1
0
10
20
30
40
50
60
Engine R oom temperature at engine installation [C]
Conversion Table
Page 72
Millimeters
Unit
Inches
Unit
0.60
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
0.0236
0.0217
0.0197
0.0177
0.0157
0.0138
0.0118
0.0098
0.0079
0.0059
0.0039
in
in
in
in
in
in
in
in
in
in
in
50
45
40
35
30
25
20
15
10
5
0
122
113
104
95
86
77
68
59
50
41
32
2010 Caterpillar
Alignment Specification
Cold alignment specification with laser:
Vertical Offset .007 engine high to .003 engine low Horizontal

Offset 0 .005
Vertical and Horizontal Angularity 0 .010
*Insure that alignment specifications are acceptable to driven equipment

and coupling manufacturer.
*If coupling will be removed for shipping from packager to the site all
removed covers and plugs must be re - installed prior to shipping.
Static Load
Static load is basically the engine load, including the weight of all fluids
within the engine and any accessories attached to the engine, plus the mean
working torque (Tn) generated in the vertical direction by the engines
moving mass during operation. While engine weight can be considered to be
evenly distributed over the engines supports, Tn will increase weight on one
side of the engine and reduce weight by an equal amount on the other side
of the engine. See the following Engine Static Forces illustration.
Engine Weight
System Description
Metric (English)
Engine Dry Weight
kg (lbs)
2010 Caterpillar
G16CM34
84800 (180779)
Page 73
Engine Static Forces
Static Torque
Engine
Speed (rpm)
Tn (kNm)
Tn
(ft * lbf)
A (m)
G16CM34
750
78
57530
1.63
F = Tn / a
F = 47582N
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2010 Caterpillar
Dynamic Load
Dynamic forces and moments result, on the one hand, from the firing
forces causing a pulsating torque, and on the other hand from the external
mass forces and moments. Dynamic forces are superimposed on the static
forces. The actual forces subjected upon the foundation will depend on the
mounting arrangement. In order to ensure that no local resonant vibrations
occur, the natural frequency of important components and structures must
be at least 30% away from the main exciting frequencies shown below.
Speed
Dynamic Forces
Ft*lb Mx
Dynamic Forces
kNm Mx
Frequency
Hz
750
12830
11060
17.4
15
50.0
100.0
Unbalanced Forces
Speed
750
Lbf Fy
Ft*lb Mx
kN Fy
kNm Mz
12830
9.590
13
Frequency
Hz
12.5
Engine Dynamic Forces
2010 Caterpillar
Page 75
Center of Gravity
Consideration of the center of gravity when planning the engine mounting
can help prevent problems with alignment due to settlement of the engine
foundation and driven equipment on the ground the equipment is set up on.
Center of Gravity
Metric (English)
G16CM34
Dimension A
mm (in)
6281 (247.28)
Dimension B
mm (in)
3260 (128.35)
Dimension C
mm (in)
650 (25.59)
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2010 Caterpillar
Auxiliary Systems Basic Data

System Description
Metric (English)
Auxiliary Skid Lifting Weight
Kg (lb)
Auxiliary Skid Dimensions
mm (in) (L / W / H)
Fuel Skid Weight US Version
kg (lb)
Fuel Skid Dimensions
mm (in) (L / W / H)
Combustion Air Filter Unit H3L2
Weight without Silencers
kg (lb)
Combustion Air Filter Unit Weight
with Silencers
kg (lb)
Combustion Air Filter Unit Dimensions
mm (in) (L / W / H)
G16CM34
13600 (30000)
6288 / 3555 / 2615
(248 / 140 / 103)
450 (992)
2116 / 600 / 1430
(83.3 / 23.6 / 56.3)
1200 (2645)
550 (1212)
2500 / 1590 / 2280
(98 / 62 / 90)
For detailed information, please refer to dedicated installation drawings of

the auxiliary system. Do not use the data above for shipping purposes.
Installation Recommendation
All installed equipment must be checked for debris or any other issue that
could cause damage when running the engine.
All systems must be cleaned to Caterpillar cleanliness requirements to
prevent damage to engine or components from foreign material that may
result from construction debris or improper storage.
Flushing and Cleaning the Interconnect Piping
Once all interconnect piping has been fabricated, it must be cleaned
and flushed prior to connection to the engine and auxiliary equipment.
Failure to properly clean all interconnecting piping will introduce
contaminants into the engine and auxiliary equipment, resulting in
2010 Caterpillar
Page 77
reduced performance, shortened long-term useful life, and up to and

including equipment failure.
Due to the myriad of different flushing methods and regional

preferences, Caterpillar Inc. does not recommend one specific flushing
process in favor of another. The specific process for guaranteeing
clean piping and interconnect piping to the Caterpillar supplied
equipment is solely the responsibility of the installing contractor / end
user. Caterpillar makes no warranty for the cleaning of any
interconnect piping, nor the cleanliness of the Caterpillar supplied
equipment except at the time Care, Custody, and Control transfers to
the contractual Buyer or end-user.
Regardless of the cleaning method used, failure to properly remove all

contaminants from the interconnect piping may result in a component
failure in that system and will result in reduced useful life of the
system. The responsibility of fabricating, cleaning, and assembling the
interconnect piping is solely the responsibility of the installing contract
or end user, whichever the case may be. Caterpillar Inc. is not
responsible for improper installation of any interconnect or component.
Regardless of whether the interconnect piping between the engine and

auxiliary equipment is stainless steel or carbon steel, the piping must
be flushed no matter the type of system.
Do not flush through valves, instrumentation, or other critical

components. Use temporary bypasses as required.
Due to the possibility that debris is introduced into the Caterpillar

supplied auxiliary skid during construction, Caterpillar requires the final
flush include the Caterpillar supplied auxiliary skid (coolant circuits and
lube oil circuit).
If the system will sit in a corrosive environment, such as excessive

moisture or extreme temperature changes, for any length of time or sit
idle for a long period of time, care must be taken to prevent corrosion.
In cases such as this, either the use of oil with a vapor space inhibitor
or laying up the system with inert gas and sealing it off airtight can
protect the system from corrosion by condensation. This must be
done with the Caterpillar engine and auxiliary equipment blanked off.
During this period of time, the system should be inspected frequently
for signs of corrosion. For more information, reference Caterpillars
documented recommendations for how and when to preserve or represerve the engine and equipment.
Caterpillar System Filter Requirements

The following table defines the maximum filter size to be used for each
system.
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2010 Caterpillar
Install the following filter equipment before the flushing tank on the return
line:
Lube Oil System: 20-micron filter.
Heavy Fuel Oil System: 10-micron filter.
Distillate Fuel Oil System: 10-micron filter.
Cooling Water System: 100-mesh screen (149-micron filter).
Compressed Air System: 100-mesh screen (149-micron filter).
Steam System: 100-mesh screen (149-micron filter).
Air Intake System: cleaned manually with no weld slag or drips visible.
Exhaust System: cleaned manually with no weld slag or drips visible.
Cleanliness is not only determined by particle size. Other factors include,

but are not limited to, particle count and type of particle. The ability to
provide an adequate flushing process including media, flow, and other
factors also must be closely monitored to assure the interconnect
components are clean as described.
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Engine Vibration
All engines produce vibration due to combustion forces, torque reactions,
and foundation designs. Vibrations can create conditions ranging from
unwanted noise to excessive stress levels. Therefore the torsional vibration
limit must not be exceeded to prevent damages to the engine and drive train.
Each engine application must be analyzed for critical linear and torsional
vibration.
Torsional Vibration Limit
The following illustration shows the measurement location of a GCM34.
All values conform to the Standard ISO 10816-6 and ISO 8528.
Frequency
Range
Unit
s-rms max.
2 10 Hz
mm
0.448
v-rms max.
10 250 Hz
mm/s
a-rms max.
Page 80
250 1000Hz
m/s
Turbo
Casing
Air Filter
Silencer
0.71
n/a
n/a
28.2
44.6
50
75
44.2
70.1
29.4
n/a
Crankcase Component*
2010 Caterpillar
Torsional Vibration Analysis (TVA) Information
For more information, please see book A1 of the technical documentation.

The following table shows engine setup.
Speed range in rpm
450-750
Break mean effective pressure in bar
16
Reciprocating mass in kg
204.2
r/l
0.217
Measurement Locations
2010 Caterpillar
Page 81
G16CM34 Engine Mass Elastic Data

Mass ID
OP-VD
AT-VD
A8/B8
A7/B7
A6/B6
A5/B5
A4/B4
A3/B3
A2/B2
A1/B1
FW
Inertia
(kgm)
30.30
2.53
121.10
121.10
121.10
121.10
121.10
121.10
121.10
123.00
378.00
Spring ID
01
02
03
04
05
06
07
08
09
10
11
Stiffness
rad /GN-m*
625.00
12.50
12.50
12.50
12.50
12.50
12.50
12.50
12.50
13.50
00.00
Diameter
(mm)
0.00
280
280
280
280
280
280
280
280
280
0
*Reciprocal value used due to calculation requirements.

Flywheel and Damper Information
System Description
Metric (English)
G16CM34
Engine Flywheel and Ring Gear Inertia

Kg-m2
378
Damper Housing Inertia outer part

Kg-m2
30.3
Damper Flywheel Inertia inner part

Kg-m2
2.53
Damper Stiffness
MN-m/rad
Damper Absolute Damping
Nm-sec/rad
Damper Permissible Elastic Torque
kNm
Damper Torque pre bar
kNm
Permissible Thermal Load
kW
Page 82
1.6
2500
Continuous: 11.2
Peak: 16.8
1.24
12
2010 Caterpillar
Crankshaft Stress Limits

System Description
G16CM34
Crankshaft Stress Limits,

combined order
48 MPa
In the event the above limits are exceeded, the customer needs to contact
Caterpillar.
Coupling
The GEISLINGER COUPLING is an elastic steel coupling with an internal

hydraulic damping system. The radial arranged leaf springs transmit the
torque elastically and oil displacement dampens the torsional vibrations.
Damping oil will be supplied through the engine lubricating oil system.
Coupling sizing is application specific and must be confirmed by the
TVA analyzed results.
Example of a Dual Geislinger Coupling
For detail installation and alignment procedure please refer to specific

installation drawing of coupling.
2010 Caterpillar
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General Installation Guidelines

To build a good working site, it is required to include some concepts and/or
ideas to get the best result as possible.
First of all, use common sense and general state-of-the-art engineering
while laying out and building the site. Also use the right materials and have
the work processes done precisely and in good workmanship to lower the
risk of unwanted downtime during operation of the site.
All delivered equipment may be installed according to manufacturers
advice. Follow instructions as close as possible to ensure the best result and
to avoid technical issues later while operating the engine and driven
equipment.
The information contained in this document outlines some of the
considerations that must be taken when receiving, storing, and installing
Caterpillar supplied equipment. This document is not intended to be an
exhaustive list of every scenario that might occur. Under no circumstances
should this document be considered a substitute for good engineering and
construction practices.
Installing the Equipment
The quality and care during the installation of the equipment is one of
the most important aspects of protecting the components as they are
installed.
Care must be used when installing any equipment or shipped loose

components to prevent damage. The installation procedures in
equipment manuals should be followed.
Successful efforts to keep debris out of the engine and auxiliary

equipment during the construction phase directly affects the
component life and the cost of flushing.
Do not remove covers from pipe flanges or instrument lines until ready
to connect them directly to a clean pipe or line.
Do not place welding grounds on or near electrical components or

mating flanges or threaded fittings.
Do not stand or otherwise use any of the equipment for working,

standing or climbing.
Do not install any interconnect piping until it has been inspected and
verified as clean.
Although flushing will be performed prior to start-up, do not assume

that contaminants entering the system piping are not harmful because
they will be removed during flushing.
Page 84
2010 Caterpillar
As Caterpillar Inc. is not responsible for site construction and

installation of the equipment, the Buyer shall be responsible for
assuring the cleanliness of the interconnecting pipes between engines
and connected auxiliary equipment including cleanliness of auxiliary
equipment supplied by others. It is the Buyers responsibility to insure
all equipment is installed and applied per Caterpillar guidelines and that
good engineering practices are strictly followed.
2010 Caterpillar
Page 85
Specific Installation
The GCM34 engine is designed for indoor use. A sufficient overhead
protection is required to protect the engine from impact of changing weather
condition, e.g. direct rain, snow and excessive sunlight.
The building shall contain all safety measures required to guarantee a safe
running environment for gas engines in terms of fire protection, ventilation
system etc.
An overhead crane is recommended to support engine maintenance and
overhaul related assembly and disassembly work.
Permanent catwalks around the engine are recommended. Please refer to
attached drawing for proposed catwalk height. Refer to drawing G16CM34
M - EID -209
Sufficient space around the engine is recommended to support
maintenance and service work activities. Please refer to attached drawings
G16CM34 M - EID-209.
The selected radiator must meet site-specific design requirements for LT
and an HT circuits.
The required heat transfer rates can be obtained from project-specific
released heat balances.
A standard balance for standard conditions you will find in the Engine Heat
Balance section of this guide.
Page 86
2010 Caterpillar
List of Standard Installation Drawings

Mechanical Installation Drawings
Electronic File Name
E02 -
229000
Mechanical-EID
Drawing No.
229000 -M-EID-201
229000 -M-EID-202
229000 -M-EID-203
229000 -M-EID-204
229000 -M-EID-205
229000 -M-EID-206
229000 -M-EID-207
229000 -M-EID-208
229000 -M-EID-209
E03 -
229000
Mechanical-PID
Engine Shipping
229000 -M-PID-001
P&ID - Legend
229000 -M-PID-002
P&ID - Lube Oil
229000 -M-PID-003
P&ID - Cooling Water
229000 -M-PID-004
P&ID - Fuel Gas
229000 -M-PID-006
229000
Mechanical-CCM
229000 -M-AUX-001
229000 -M-AUX-002
P&ID - Air Inlet &

Exhaust
P&ID - Starter/Barring
Device
Combined Cooling
Module
Combined Cooling
Module
E05 -
229000
Mechanical-FS
229000 -M-FUE-001
Fuel System
E06 -
229000
Mechanical-CCV
229000 -M-CCV-001
Crankcase Ventilation
System
E07 -
229000
MechanicalCoupling
229000 -G1 07251
Coupling
229000 -G0 02557 A
Coupling
229000 -M-AIS-001
Air Inlet System
E08 -
229000
Mechanical-AIS
2010 Caterpillar
Update
Engine Installation
Drawings
Engine Installation
Drawings
Engine Installation
Drawings
Engine Installation
Drawings
Engine Installation
Drawings
Engine Installation
Drawings
Engine Installation
Drawings
Engine Installation
Drawings
Engine Installation
Drawings
229000 -M-EID-210
229000 -M-PID-005
E04 -
Description
Page 87
Electrical Installation Drawings

Electronic File Name
Drawing-No.
Description
E09 -
229000 Electrical Consumer
229000 -E-ECL-001
Electrical Consumer List
E10 -
229000 Electrical-EES
229000 -E-EGN-001
Engine Electrical System
E11 -
229000 Electrical-Sensors
229000 -E-EGN-002
Devices, Sensors & Actuators
E12 -
229000 Electrical-Set Points
229000 -E-EGN-003
List of Measuring Points Engine
E13 -
229000 Electrical-LCP
229000 -E-LCP-000
Local Control Panel
229000 -E-LCP-001
Local Control Panel
229000 -E-LCP-002
Local Control Panel
229000 -E-LCP-003
Local Control Panel
229000 -E-LCP-004
Local Control Panel
229000 -E-LCP-005
Local Control Panel
229000 -E-LCP-006
Local Control Panel
229000 -E-LCP-007
Local Control Panel
229000 -E-LCP-008
Local Control Panel
229000 -E-LCP-009
Local Control Panel
229000 -E-LCP-010
Local Control Panel
229000 -E-LCP-011
Local Control Panel
229000 -E-LCP-012
Local Control Panel
229000 -E-LCP-013
Local Control Panel
229000 -E-LCP-014
Local Control Panel
229000 -E-LCP-015
Local Control Panel
229000 -E-LCP-016
Local Control Panel
229000 -E-LCP-017
Local Control Panel
229000 -E-LCP-018
Local Control Panel
229000 -E-AUX-001
AUX Skid - Power Wiring
229000 -E-AUX-002
AUX Skid - Analog Comb Module
229000 -E-AUX-003
AUX Skid - Analog Output
229000 -E-AUX-004
AUX Skid - Analog Input
229000 -E-AUX-005
AUX Skid - Digital Output
229000 -E-AUX-006
AUX Skid - Panel Layout
E14 -
Page 88
229000 Electrical-CCM
2010 Caterpillar
E15 - 229060 Electrical-CMP
229000 -E-CMP-001
CMP - Panel Wiring
229000 -E-CMP-002
CMP - Panel Wiring
229000 -E-CMP-003
CMP - Panel Wiring
229000 -E-CMP-004
CMP - Panel Wiring
229000 -E-CMP-005
CMP - Panel Wiring
229000 -E-CMP-006
CMP - Panel Wiring
229000 -E-CMP-007
CMP - Panel Wiring
229000 -E-CMP-008
CMP - Panel Wiring
229000 -E-CMP-009
CMP - Panel Wiring
229000 -E-CMP-010
CMP - Panel Wiring
E16 -
229000 Electrical-FS
229000 -E-FUE-002
Fuel System
E17 -
229000 Electrical-M2M
229000 -E-M2M-001
M2M Satellite Communication
2010 Caterpillar
Page 89
Engine Shipping and Preservation

The Caterpillar GCM34 is shipped with all items of the ordered scope of
supply from the factory to the site according to the terms in the contractual
agreement.
The engine is being delivered seaworthy packed and preserved following
Caterpillar standard N 576.
Engine Transportation
Engines transportation dimensions and weights, lifting information and

information about the auxiliary equipment can be found in attached drawings
and also in the dedicated chapter of the Application and Installation Guide.
Storing the Equipment
The equipment must be properly stored properly before, during, and

after the construction phase of the project.
As different components of equipment from Caterpillar and other

suppliers are received on site, they must be properly stored until that
individual component is required to be installed.
All material should be located and inventoried in a secure and weather

protected lay down area to prevent loss and damage during
construction.
All material must be stored in dry conditions to prevent damage due to

moisture ingress or internal/external rust and corrosion.
Any machined surfaces must be preserved as necessary and inspected

during the storage term, regardless of time length, to determine if any
action is required to prevent damage beyond surface rust.
Tarps must not be removed from the engines until absolutely

necessary to prevent deterioration of finish and components on
engine.
Reference Caterpillars documented recommendations for how and

when to preserve or re-preserve the engine and auxiliary equipment.
Engine Preservation
For detailed description, please refer to the respective data sheet of factory
standard preservation. There are two types of preservation.
N576-3.1 Engine inside Preservation
N576-3.3 Engine outside Preservation
The GCM34 features heavy-duty preservation by factory standard.

If the engine outside preservation is not damaged while in shipping, the
preservation will last one year after the engine leaves the factory. The
Page 90
2010 Caterpillar
preservation process by Vapor Corrosion Inhibitors (VCI) is done to protect

the engine against moisture and other influences, which can occur during
transport or storage.
The outside VCI foil preservation must be visually controlled every 3
months for proper condition. It must be checked for damage and cracks.
If storage times will exceed the one-year period, the preservation must be
renewed following Caterpillar standards N576.
For storage in special conditions, like arctic environment or desert
environment, all details concerning preservation must be determined with a
Caterpillar Global Petroleum representative.
Engines and all auxiliary equipment must be stored in a dry warehouse or
similar building with minimal heating in cold conditions.
A document describing the required action to ensure preservation and the
function of the VCI components is available from your Caterpillar
representative.
Any auxiliary equipment delivered within the Caterpillar scope of supply is
preserved for 1-year storage inside of a building.
To keep full warranty, a visual inspection must be performed and
documented every 3 months.
N 576-3.2 Tectyl Heavy- Duty Outside Preservation
Only for Overseas preservation
Storage in the open, protected from moisture, up to 1 year.
N 576-3.3 Engine Inside Preservation

Up to 1 year, engine is protected from Moisture
Main running gear and internal mechanics
Painting
The durability and effectiveness of the paint dependents on proper packing,
- transport, and correct storage, i.e. the engine must be protected from
moisture.
Any injury of the VCI foil will end up in the lost of the preservation for the
engine.
With a damaged VCI foil the guarantied preservation time of 1 year is
reversed.
Checks of undamaged VCI foil must be carried out at regular intervals.
If the above requirements are not met, all warranty claims in connection
with corrosion damages shall be excluded.
Appearance of the Engine
Casting with red oxide antirust paint
2010 Caterpillar
Page 91
Pipes and machined surfaces left as bare metal
Attached components with colors of the manufacturers
Surface sealed with clear varnish
Bare metal surfaces with light preservation
N 576-4.3-Painting
Without VCI Packaging:
Short-term storage in the open, protected from moisture, maximum 4
weeks
With VCI Packaging:
Storage in the open, protected from moisture, up to 1 year
Appearance:
Surface mostly painted with varnish.
Bare metal surfaces provided with light or heavy -duty preservation.
N 576-5.2 VCI Packaging

Storage in the open, protected from moisture, up to 1 year.
Applies for painting according to application groups N 576-4 to 576-4.4.
Not applicable for Tectyl outside preservation according to application
groups N 576-3.1 to 576-3.2
Description:
On the engine or engine generator set VCI impregnated flexible PU
foam mats are arranged by means of tie wraps. Kind and scope to be
agreed upon.
The mats are to be hung up in free position and should be not come
into contact with the painted surface.
N 576-5.2 Suppl.1, Information Panel for VCI Preservation and Inspection

Applies for VCI packaging as per application group N576-5.2.
Description:
This panel provides information on the kind of initial preservation and
instructions for inspection.
It is arranged on the transport frame or on the covering sheet on each

side so as to be easily visible.
N 576-5.1 Corrosion Protection Period, Check and Preservation

Applies to all engines or engine generator sets with inside or outside
storage.
Description:
Definitions of corrosion protection period, check, and preservation.
Page 92
2010 Caterpillar
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2010 Caterpillar
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APPLICATION

Scope of Supply ..............................................................17

Flex Connection Installation ..........................................40

Switches & Lamps .......................................................61

Engine Shipping and Preservation ......................................90

Information contained in this publication may be considered confidential.

Application and Installation Guide

Technical Data G16CM34 Engines

Technical Information G16CM34 Engines

Reduced number of components

Simple maintenance, assembly and dismantling

Split connecting rod for rapid and error-free assembly

The most renowned feature is the long-stroke, which improves

Technical Data G16CM34 Engines

Application and Installation Guide

Application and Installation Guide

Technical Data G16CM34 Engines

The cylinder liners are manufactured of a natural hardened centrifugal cast

Technical Data G16CM34 Engines

Application and Installation Guide

General Engine Data

Engine Power @ 750 rpm

Engine Power @ 450 rpm

Firing Order CCW

Combustion Air Flow

Engine operation altitude limit w/o derate

Application and Installation Guide

Technical Data G16CM34 Engines

Lubricating Oil Capacity (Deep Oil Pan)

Lubricating Oil Consumption

Engine Dimensions (Length/Width/Height)

Wet weight approx. (including lubricating oil

Technical Data G16CM34 Engines

Application and Installation Guide

0.5 gNOx/bhp and hour

0.7 gNOx/bhp and hour

Application and Installation Guide

Technical Data G16CM34 Engines

Sound Level Data

Measurement Surface Area

Measurement Distances From Engine

Sound Level in Linear Decibels (dB)

Sound power level (dB re 1e-12W)

Exhaust Sound Level Linear Decibels (dB)

Sound Level in Linear Decibels (dB)

Sound power level (dB re 1e-12W)

Measuring point is at 3 m [9.8 ft] after the turbocharger, at the open

Technical Data G16CM34 Engines

Application and Installation Guide

Combustion Air Sound Level Linear Decibels (dB)

Sound Level in Linear Decibels (dB)

Combustion Air Sound

Sound power level (dB re 1e-12W)

A weighted Sound Power Spectrum is available on request.

Application and Installation Guide

Technical Data G16CM34 Engines

Engine Startup Cycle

Minimum Start Time from stop to full load: 205 seconds.

Standard Start Time from stop to full load: 880 seconds.

Compressors typically get loaded in a single load step from approx. 10

GCM34 Starting Time

Technical Data G16CM34 Engines

Application and Installation Guide