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< Product: POWER MODULE

Model: PMG3516 POWER MODULE KAO
Configuration: G3516B Power Module KAD00001-UP

Operation and Maintenance Manual

PMG3516 Power Module
Media Number -SEBU8723-01 Publication Date -01/04/2012 Date Updated -11/04/2012

i04854895

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.

An authorized operator may perform the maintenance items with daily intervals. An authorized
operator may perform the maintenance items with intervals of every week. The maintenance that is
recommended for all other maintenance intervals must be performed by an authorized service
technician or by your Cat dealer.

The user is responsible for the performance of all maintenance which includes the following items:
performing all adjustments, using proper lubricants, fluids, and filters and replacing old components
with new 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.

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

Choose the interval that occurs first in order to determine the correct maintenance interval: fuel
consumption, service hours and calendar time. Products that operate in severe operating conditions
may require more frequent maintenance.

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

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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/Clean/Replace
Engine Oil Filter - Change
Fumes Disposal Filter Element - Replace
Generator - Dry
Generator Bearing - Lubricate
Generator Set - Test
Generator Winding - Test
Generator Winding Insulation - Test
Methane Gas Detector
Overhaul Considerations
Rotating Rectifier - Inspect/Test
Space Heater - Test
Valve Stem Projection - Measure/Record
Varistor - Inspect

Daily
Control Panel - Inspect/Test
Coolant Level - Check
Electrical Connections - Check
Electrohydraulic System - Inspect
Engine Air Cleaner Service Indicator - Inspect
Engine Oil Level - Check
Fan Drive Bearing - Lubricate
Fan Motor - Lubricate
Fuel Filter Differential Pressure - Check
Fumes Disposal Filter Differential Pressure - Check
Generator - Inspect
Generator Bearing Temperature - Test/Record
Generator Load - Check
Jacket Water Heater - Check
Makeup Oil Tank - Fill
Stator Winding Temperature - Test

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Voltage and Frequency - Check

Walk-Around Inspection

Every Week
Automatic StarUStop - Inspect
Battery Charger - Check
Power Factor - Check

Initial 250 Service Hours

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

Every 250 Service Hours

Battery Electrolyte Level - Check
Coolant Sample (Level 1) - Obtain

Every 500 Service Hours

Fumes Disposal Filter - Drain

Initial 1000 Service Hours

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

Every 1000 Service Hours

Aftercooler Condensation - Drain
Alternator - Inspect
Belts - Inspect/Adjust/Replace
Coolant Sample (Level 2) - Obtain
Crankcase Pressure - Measure
Crankshaft Vibration Damper - Inspect
Engine Crankcase Breather - Clean
Engine Oil - Change
Engine Oil Sample - Obtain
Engine Valve Lash and Bridge - Check
Exhaust Piping - Check
Hoses and Clamps - Inspect/Replace
Ignition System Timing - Check/ Adjust
Inlet Air System - Check
Radiator - Clean

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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 Year
Engine Perfonnance - Test

Every 3000 Service Hours

Spark Plugs - Inspect/Replace

Every 4000 Service Hours

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

Every 8000 Service Hours

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

Between 10 000 and 20 000 Service Hours

Overhaul (Top End)

Every 24 000 Service Hours or 3 Years

Coolant (DEAC) - Change

Between 30 000 and 60 000 Service Hours

Overhaul (In-Frame)

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Between 50 000 and 100 000 Service Hours

Overhaul (Major)

Overhaul
Generator Bearing - Inspect

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