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Product: GENERATOR SET

Model: G3516B GENERATOR SET ZBC
Configuration: G3516B Generator Set ZBC00001-UP

Operation and Maintenance Manual

G3516B and G3520B Generator Sets
Media Number -SEBU7566-04 Publication Date -01/11/2004 Date Updated -08/11/2004

i02225696

Maintenance Interval Schedule - Standard

SMCS - 1000; 4450; 7500

Before performing any operation or maintenance procedures, ensure that the Safety
Information, warnings, and instructions are read and understood.

The maintenance that is recommended for Every Week can be performed by an authorized operator.
The maintenance that is recommended for the subsequent maintenance intervals must be performed
by an authorized service technician or by your Caterpillar dealer.

Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must be performed.

When Required

Bearing (Ball) - Lubricate

Engine Air Cleaner Element - Replace
Engine Oil Filter - Change
Fumes Disposal Filter Element - Replace
Generator - Dry
Generator Set - Test
Insulation - Test
Overhaul Considerations
Rotating Rectifier - Test
Space Heater - Check
Valve Stem Projection - Measure/Record
Varistor - Test
Winding - Test

Daily

Air Inlet Filter - Check

Air Starting Motor Lubricator Oil Level - Check
Air Tank Moisture and Sediment - Drain
Bearing Temperature - Measure/Record
Cooling System Coolant Level - Check
Electrical Connections - Check
Electrohydraulic System - Inspect

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Engine Air Cleaner Service Indicator - Inspect

Engine Air Precleaner - Clean
Engine Oil Level - Check
Fuel System Fuel Filter Differential Pressure - Check
Fumes Disposal Filter Differential Pressure - Check
Generator - Inspect
Generator Load - Check
Power Factor - Check
Stator Winding Temperature - Measure/Record
Voltage and Frequency - Check
Walk-Around Inspection

Initial 250 Service Hours

Crankcase Blowby - Measure/Record

Cylinder Pressure - Measure/Record
Engine Oil Sample - Obtain
Valve Stem Projection - Measure/Record

Every 250 Service Hours

Battery Electrolyte Level - Check

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) - Obtain

Fumes Disposal Filter - Drain

Initial 1000 Service Hours

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

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

Every 1000 Service Hours

Aftercooler Condensation - Drain

Alternator - Inspect
Belts - Inspect/Adjust/Replace
Cooling System Coolant Sample (Level 2) - Obtain
Crankcase Pressure - Measure
Crankshaft Vibration Damper - Inspect
Engine Crankcase Breather - Clean
Engine Oil - Change
Engine Oil Filter (Auxiliary) - Change
Engine Oil Filter - Change
Engine Oil Sample - Obtain
Engine Valve Lash and Bridge - Adjust
Exhaust Piping - Inspect
Gas Pressure Regulator Condensation - Drain
Hoses and Clamps - Inspect/Replace
Ignition System Spark Plugs - Inspect/Adjust/Replace
Ignition System Timing - Check/Adjust

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Inlet Air System - Inspect

Oxygen Sensor - Calibrate
Radiator - Clean

Every 2000 Service Hours

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

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

Every 4000 Service Hours

Air Starting Motor Lubricator Bowl - Clean

Crankcase Blowby - Measure/Record
Cylinder Pressure - Measure/Record
Electrohydraulic System Oil - Change
Electrohydraulic System Oil Filter - Change
Engine Mounts - Check
Engine Protective Devices - Check
Exhaust Bypass - Inspect
Fuel Metering Valve Screen - Check
Starting Motor - Inspect
Water Pump - Inspect

Every 8000 Service Hours

Fumes Disposal Filter Element - Replace

Rotating Rectifier - Check
Turbocharger - Inspect
Water Temperature Regulator - Replace

Between 10 000 and 20 000 Service Hours

Bearing - Inspect
Overhaul (Top End)

Every 24 000 Service Hours or 3 Years

Cooling System Coolant (NGEC) - Change

Between 30 000 and 60 000 Service Hours

Bearing - Inspect
Overhaul (In-Frame)

Between 50 000 and 100 000 Service Hours

Bearing - Inspect
Overhaul (Major)

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Copyright 1993 - 2010 Caterpillar Inc. Fri Mar 19 18:09:14 UTC-0300 2010
All Rights Reserved.
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