Service Information System

Page 1 of 3

Operation and Maintenance Manual

G3500 Engines
Media Number -SEBU8099-02 Publication Date -01/04/2007 Date Updated -27/04/2007

i02729402

Maintenance Interval Schedule

SMCS - 1000; 4450; 7500 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, filters, and the installation of new components due to normal wear and aging. The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed. Use fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order 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 intervals must be performed.

When Required
Engine Air Cleaner Element - Replace Engine Oil Filter - Change Overhaul Considerations Throttle Control Valve - Check Valve Stem Projection - Measure/Record

Daily
Air Starting Motor Lubricator Oil Level - Check Air Tank Moisture and Sediment - Drain Cooling System Coolant Level - Check Engine Air Cleaner Service Indicator - Inspect Engine Oil Level - Check Fuel System Fuel Filter Differential Pressure - Check Walk-Around Inspection

Every 250 Service Hours

Battery Electrolyte Level - Check Cooling System Coolant Sample (Level 1) - Obtain Cooling System Supplemental Coolant Additive (SCA) - Test/Add Engine Oil Sample - Obtain

Initial 1000 Service Hours

https://sisweb.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/full... 09/27/2011

Service Information System

Page 2 of 3

Engine Mounts - Check Engine Speed/Timing Sensor - Clean/Inspect Valve Stem Projection - Measure/Record

Every 1000 Service Hours

Alternator - Inspect Belts - Inspect/Adjust/Replace Carburetor Air/Fuel Ratio - Check/Adjust Crankshaft Vibration Damper - Inspect Engine Crankcase Breather - Clean Engine Oil - Change Engine Oil Filter - Change Engine Valve Lash and Bridge - Adjust Gas Pressure Regulator Condensation - Drain Hoses and Clamps - Inspect/Replace Ignition System Spark Plugs - Inspect/Adjust/Replace Ignition System Timing - Check/Adjust Inlet Air System - Inspect Radiator - Clean

Every 1000 Service Hours or 6 Weeks

Aftercooler Condensation - Drain

Every 2000 Service Hours

Actuator Control Linkage - Lubricate Cooling System Coolant Sample (Level 2) - Obtain Engine Speed/Timing Sensor - Clean/Inspect

Every 4000 Service Hours

Air Starting Motor Lubricator Bowl - Clean Crankcase Blowby - Measure/Record Cylinder Pressure - Measure/Record Engine Mounts - Check Engine Protective Devices - Check Exhaust Bypass - Inspect Starting Motor - Inspect Water Pump - Inspect

Every 8000 Service Hours

Turbocharger - Inspect Water Temperature Regulator - Replace

Between 9000 and 16 000 Service Hours

Overhaul (Top End)

https://sisweb.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/full... 09/27/2011

Service Information System

Page 3 of 3

Every 24 000 Service Hours or 3 Years

Cooling System Coolant (NGEC) - Change

Between 27 000 and 48 000 Service Hours

Overhaul (In-Frame)

Between 45 000 and 80 000 Service Hours

Overhaul (Major)

Copyright 1993 - 2011 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Tue Sep 27 15:37:35 EDT 2011

https://sisweb.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/full... 09/27/2011