G3516 Generator Set ZBA00001-UP(SEBP3860 - 42) - Documentation https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnu...

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Product: GENERATOR SET
Model: G3516 GENERATOR SET ZBA01313
Configuration: G3516 Generator Set ZBA00001-UP

Operation and Maintenance Manual

G3500 Generator Sets
Media Number -SEBU7551-08 Publication Date -01/07/2014 Date Updated -20/09/2016

i06819313

Maintenance Interval Schedule - Bio Gas

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
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 mileage, 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.

Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

All of the following will affect the oil change interval: operating conditions , fuel type , oil type, and size of the oil sump. Scheduled oil
sampling analyzes used oil to determine if the oil change interval is suitable for your specific engine.

Refer to this Operation and Maintenance Manual , "Engine Oil and Filter - Change" to determine the oil change interval that is suitable
for your specific engine.

To determine the maintenance intervals for the overhauls, refer to this Operation and Maintenance Manual , "Maintenance
Recommendations" .

Unless other instructions are provided, perform maintenance and perform repairs under the following conditions:

The starting system is disabled.

The engine is stopped.

The generator does not pose an electrical shock hazard.

The generator is disconnected from the load.

When Required

Battery - Replace
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Engine Oil - Change
Fuel Filtration System - Service
Generator - Dry
Generator Set - Test
Generator Winding - Test
Generator Winding Insulation - Test
Overhaul Considerations
Rotating Rectifier - Inspect/Test
Valve Stem Projection - Measure/Record
Varistor - Check

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Daily

Air Inlet Filter - Inspect/Clean/Test

Air Starting Motor Lubricator Oil Level - Check
Air Tank Moisture and Sediment - Drain
Control Panel - Inspect/Test
Coolant Level - Check
Electrical Connections - Check
Engine Air Cleaner Service Indicator - Inspect
Engine Air Precleaner - Check/Clean
Engine Oil Level - Check
Fuel Filter Differential Pressure - Check
Generator - Inspect
Generator Bearing Temperature - Test/Record
Generator Load - Check
Power Factor - Check
Space Heater - Test
Stator Winding Temperature - Test
Voltage and Frequency - Check
Walk-Around Inspection

Every 125 Service Hours or Weekly

Engine Oil Sample - Obtain

Every 250 Service Hours

Coolant Sample (Level 1) - Obtain

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Every 250 Service Hours or 2 Weeks

Battery Electrolyte Level - Check

Initial 1000 Service Hours or 6 Weeks

Engine Speed/Timing Sensor - Clean/Inspect

Valve Stem Projection - Measure/Record

Every 1000 Service Hours

Engine Valve Lash - Check

Every 1000 Service Hours or 6 Weeks

Aftercooler Condensation - Drain

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

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Every 2000 Service Hours or 3 Months

Actuator Control Linkage - Lubricate

Engine Speed/Timing Sensor - Clean/Inspect
Generator Bearing - Lubricate
Generator Set Vibration - Inspect
Stator Lead - Check

Every 4000 Service Hours or 6 Months

Air Starting Motor Lubricator Bowl - Clean

Alternator - Inspect
Crankcase Blowby - Test/Record
Cylinder Pressure - Test/Record
Cylinders - Inspect
Engine Mounts - Inspect
Engine Protective Devices - Check
Exhaust Bypass - Inspect
Starting Motor - Inspect
Turbocharger - Inspect
Water Pump - Inspect

Between 7500 and 8000 Service Hours

Overhaul (Top End)

Every 8000 Service Hours

Coolant Sample (Level 2) - Obtain

Every 8000 Service Hours or 1 Year

Coolant Temperature Regulator - Replace

Rotating Rectifier - Check

Every Year

Spark Plugs - Inspect/Adjust/Replace

Between 22 500 and 24 000 Service Hours

Overhaul (In-Frame)

Every 24 000 Service Hours or 3 Years

Coolant (DEAC) - Change

Coolant (NGEC) - Change

Between 37 500 and 40 000 Service Hours

Generator Bearing - Inspect

Overhaul (Major)

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