G3500H 60Hz Generator Sets Caterpillar

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, and filters. The user is also responsible for the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

When Required

Battery - Recycle
Battery - Replace
Battery or Battery Cable - Disconnect
Coolant Sample (Level 2) - Obtain
Engine Air Cleaner Element - Replace
Generator - Dry
Generator Set - Test
Generator Set Alignment - Check
Generator Winding - Test
Overhaul Considerations
Stator Winding Temperature - Test
Throttle Control Valve - Check
Varistor - Inspect

Daily

Coolant Level - Check
Drive Gearbox Oil Level - Check
Engine Air Cleaner Differential Pressure - Check
Engine Oil Filter Differential Pressure - Check
Engine Oil Level - Check
Fuel Filter Differential Pressure - Check
Fumes Disposal Filter Differential Pressure - Check
Generator Bearing Temperature - Test/Record
Generator Load - Check
Jacket Water Heater - Check
Power Factor - Check
Voltage and Frequency - Check
Walk-Around Inspection

Initial 250 Service Hours

Valve Stem Projection - Measure/Record

Every 250 Service Hours

Coolant Sample (Level 1) - Obtain
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Drive Gearbox Oil Heater - Test
Drive Gearbox Oil Sample - Obtain
Engine Oil Sample - Obtain
Fumes Disposal Filter - Drain
Space Heater - Test

Every 1000 Service Hours

Alternator - Inspect
Battery Electrolyte Level - Check
Belts - Inspect/Adjust/Replace
Crankcase Pressure - Measure
Crankshaft Vibration Damper - Inspect
Engine Crankcase Breather - Clean
Fumes Disposal Filter Element - Inspect
Hoses and Clamps - Inspect/Replace
Inlet Air System - Check
Water Pump - Inspect

Every 2000 Service Hours

Engine Oil and Filter - Change
Flexible Coupling (Rubber) - Inspect
Gas Filter Condensation - Drain
Generator Bearing - Lubricate
Generator Set Vibration - Inspect
Spark Plugs - Inspect/Adjust/Replace
Stator Lead - Check

Every 4000 Service Hours

Crankcase Blowby - Test/Record
Cylinder Pressure - Test/Record
Drive Gearbox Oil - Change
Drive Gearbox Oil Filter - Clean/Inspect
Engine Mounts - Inspect
Engine Protective Devices - Check
Engine Valve Lash and Bridge - Check
Flexible Coupling (Silicone Compression) - Inspect
Ignition System Timing - Check/Adjust
Nitrogen Oxide Sensor - Calibrate
Starting Motor - Inspect
Valve Stem Projection - Measure/Record

Every 8000 Service Hours

Coolant Temperature Regulator - Replace
Drive Gearbox Oil Filter - Replace
Drive Gearbox Sump Oil Screen - Inspect/Clean
Engine Speed/Timing Sensor - Clean/Inspect
Generator Bearing - Inspect
Generator Winding Insulation - Test
Ignition Transformer Extender - Replace
Rotating Rectifier - Check

Every 10 000 Service Hours

Nitrogen Oxide Sensor - Replace

Between 18 000 and 22 000 Service Hours

Overhaul (Top End)
Turbocharger - Inspect

Every 24 000 Service Hours or 3 Years

Coolant (NGEC) - Change

Between 35 000 and 45 000 Service Hours

Overhaul (In-Frame)

Between 70 000 and 90 000 Service Hours

Overhaul (Major)