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Basic Training
On
Operation & Maintenance

Conducted by: 
Engineer (Mechanical)
ZICOM Equipment Pte. Ltd

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Good Morning
Welcome to this Training
session

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Let’s go for a simple question.

What is compressor?

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The answer is
Compressor is nothing but a pump.
Both compressor and pump increase the pressure of fluid and both
can transport the fluid through a pipe.

Then what is the difference betn Pump and compressor?

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A gas compressor is a mechanical

device that increases the pressure of a
gas by reducing/compressing its
volume to transport gas through
pipeline. As gases are compressible,
the compressor reduces the volume
Gas Compressor
of gas to increase the pressure.
On the other hand, as liquids are
relatively incompressible the main
action of a pump is to transport
liquids trough pipeline
Pump

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Requirement of Wellhead Compressor

 Gas wells that are nearly depleted are often abandoned. Even though
considerable amounts of gas and oil could still be extracted. The
remaining oil and gas can no longer be recovered efficiently and cost-
effectively with conventional methods. The pressure is not enough to
transport produced gases or liquids upwards through the production
pipeline.
 In order to facilitate the production of mature gas fields, a possible
solution is installing compression. By introducing compression, the
well head pressure is reduced allowing larger gas flow rates. Wellhead
compression (WHC) is the solution by which a compressor extends
the life of oil and gas wells and boosts their production output.
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Operation

Compressors are an integral part of the production process. They are used to
increase the line pressure so that gas can be delivered to the processing plants
and/or sales lines.
Compressor stations are part of the natural gas pipeline network that moves
natural gas from individual producing well to end users. As natural gas moves
through a pipeline, distance, friction, and elevation differences slow the
movement of the gas, and reduce pressure. Also during prolonged production the
reservoir pressure declined.
Compressor stations are placed strategically within the wellhead to gathering
and to and in between transportation pipeline network to help maintain the
pressure and flow of gas to end user. So, Compressors are used for natural gas
gathering, transport, processing and storage, etc.
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Compressor Packages

According to its strategic use and depends on its operation

these are
1)Wellhead compressor packages, which are employed over
here.
2) Booster compressor packages:
to increase the pressure (even intentional reduction, depends Well head Compressor packages
on process requirement) to cater the grid line pressure, such
compressors are under operation at Sylhet Gas Fields Limited,
and bkb
to boost up the grid pipeline pressure to feed the customer as
like as Muchai, Ashuganj and Elenga hubs where compressors
are in use for Gas Transmission Company Limited.
Booster Compressor packages

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Types of Compressor

In gas industry there are many types of compressors are in use. Some of the
prominent are as below:
 Positive Displacement type: 
Reciprocating compressor
Single Acting type
Double Acting type  Single Acting Compressor Double Acting Compressor

Rotary compressor
Screw type
Vane type
Screw type Compressor Vane type Compressor

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Types of Compressor

Dynamic type
Centrifugal compressor
Axial compressor
Turbo expander Compressor Assembly

Centrifugal Compressor Axial Compressor Turbo expander Compressor

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Types of Driver for Compressor

Reciprocating engines
Gas turbines and
Electric motors.
 

Reciprocating Engine Gas Turbine Electric Motor

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Types of Driver for Compressor

Reciprocating compressors are mostly driven by natural gas-powered reciprocating engines.

Gas turbines rely on the hot exhaust gas discharged by a gas generator to drive a power turbine.
The output power from the turbine shaft is used to drive the pipeline gas compressor.

Rotary compressor/Centrifugal/Axial compressors are usually driven by electric motors.

 

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Maintenance

In order to keep the operation smooth and safe it is necessary to check the parameters of the operation.
Whether the parameters are up to mark or not; keeping in touch with that is considered as maintenance.
Proper maintenance can mitigate troubleshoot a long way

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Operation of the Wellhead Gas Compression Process

Layout
• Operation starts as the well stream enter the gas gathering Manifold, maintaining the desired
pressure by dedicated PCV for each stream.
• As the gas travels to 3 Phase Production separation vessel where separate free liquids from gas stream
and solids or other particulate matter that may be in the gas stream are also filtered away.
• After that the dried gas moves to the Pre-cooler for obtaining desired temperature. Later it goes to
the compressor cylinder for gas compression through the suction scrubber for further removal of free
liquid from gas to achieve dried gas.
• Thereafter compressed gas travels to after cooler for further reduction of temperature to gain aimed
temperature. Later it goes again to the gathering manifold to distribute gas at particular gas plant
through the discharge scrubber for removing liquid due temperature fall. Compressed gas is measured
by ultrasonic flow meter during travelling from discharge scrubber to Gas gathering manifold.
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Engine Identification View

(REPEATATION!)
1 1.MAS valve
2.Centrifugal Oil Filter
13 14 3.Starter motor air /Gas Inlet
2 Connection
4. Lube Oil Dipstick
5. Lube Oil Filler
6. Crankcase pressure relief door.
7. Emergency Shutdown Button (E­-
Stop)
8. Pre lube pump
10 9 9. ECU
3 10. HMI
11. Auxiliary water Inlet
12 7 12. Engine Jacket water Inlet
13. Engine Air Inlet
15 14. Lube oil Filter
5 4 15. Starter motor Air/Gas Exhaust
6
connection.
11
8

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Engine Specifications
(Quick review)
4-cycle, lean burn, prechamber Engine Specifications
Engine Model: 16V275GL+
Aspiration, GSI: Turbocharged and intercooled
Number of cylinders: V-16
Bore x stroke: 10.83x11.81 in. (275x300mm)
Compression ratio: 9.0:1
Speed range: 750-1000 rpm
(Can add few more points)

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Engine Specifications
Cooling System Quick review
Jacket coolant capacity, engine only: 133 gal ( 503 L)
Auxiliary coolant capacity: 40 gal (51 L)
High Jacket Coolant Temperature Shutdown: 93 °C(200 °F)
Exhaust System
Maximum permissible backpressure : 508 mm-H2O(15 inch-H2O)
Starting System
Air starting pressure: 862-1034kpa (125-150 psi))

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Compressor Specifications
(Quick Review)
Number of Throws: 4
Rated Power: 5200 BHP
Bore: 9.625 in
Stroke: 6.75 in
Maximum RPM: 1000
Piston Speed: 1100 FPM (5.59 m/s)
(Can add few more points)

90 MMSCFD Wellhead Gas Compressor

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On other sessions, you have come across over production philosophy. Let us take a
glance through compressor package operation and maintenance.

ROUTINE START­UP PROCEDURE

ENGINE SHUTDOWN PROCEDURES
EMERGENCY SHUTDOWN
ENGINE TROUBLESHOOTING
ESM ALARM CODES, PROBABLE CAUSE AND REMEDY
ESM SHUTDOWN FAULT CODES, PROBABLE CAUSE AND REMEDY
MAINTENANCE SCHEDULE FOR ENGINE

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Routine Startup Procedure

1. Complete all prestart activities and checks.
2. Reset all engine protection switches and devices.
3. Set operating speed to 750 rpm, pressure between
35 kPa (5 psi) and 200 kPa (30 psi). Allow engine to
crank for 15 seconds to verify adequate purging.
4. Confirm engine coolant and lube oil are least 16°C
(60° F) for reliable starting.
5. Open the manual gas shutoff valve, if closed.
6. Initiate prelude/start cycle
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Routine Startup Procedure

7. Engine should start in the first 7-8 seconds of cranking cycle. (A 5 second delay from crank
initiation to main gas shutoff valve opening is programmed into the ESM to purge unburnt
fuel from previous start attempts from the engine and fuel system. When the engine starts
listen carefully for unusual noises. If a problem is suspected, stop the engine immediately.

8. Warm engine by running with little or no load until oil pressure is 415-450 kPa (60-65 psi)
and intake manifold temperature exceeds 38° C( 100 °F). For standby units, jacket water
heating to 43 °C(110 ° F) is required.

9. Gradually apply load to avoid overloading engine.

10. If the engine is difficult to start or will not run properly, see the troubleshooting and retry

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Engine Shutdown Procedure

1. Gradually start the engine load.

2. Operate engine at no load for 5 minutes to cool

down engine temperatures.

3. Post lube engine for 90 seconds. ESM system is

programmed to automatically post lube engine.

4. Shut down engine using customer supplied control

panel.

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Engine Shutdown Procedure

5. Gradually reduce engine load.

6. Operate engine at no load for 5 minutes to cool down engine

temperatures

7. Post lube engine for 90 seconds. ESM system is programmed to

automatically post lube engine

8. Shut down engine using customer supplied control panel

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Engine Shutdown Procedure

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Emergency Shutdown
When the red emergency stop
 
button located on either side of the  
 
engine is pressed, the engine will  
 
perform an emergency stop (see  
 
Figure 3.00­14 and Figure 3.00­15).  
   
   
   
 
 
 
 
 
 
 
 
 
 
 

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Engine Troubleshooting
SYMPTOM PROBABLE CAUSE REMEDY

Insufficient cranking speed: Build up air/gas pressure

Low starting air/gas pressure 100 – 125 rpm required to start
Oil temperature too low or viscosity engine Preheat oil
too high Confirm correct weight oil has been
used

Engine will crank, but will not start. Insufficient fuel supply or fuel pressure Check gas pressure during cranking
Faulty spark plugs Clean or replace
Stuck linkage-governor, wastegate,
Repair or replace
compressor bypass
Gas regulator damage Repair or replace
Control faults See ESM FAULT CODES

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Insufficient fuel supply Check gas pressure
Engine overloaded Check driven machine load
ESM shutdown faults See ESM FAULT CODES
Air leaks in intake system Find and correct as required.
Gas admission valve sticking, Repair or replace gas
Engine stops suddenly. causing engine misfire admission valve(s)
Worn or faulty spark plug causing engine Clean or replace spark plug(s)
misfire
Leaking cylinder fire ring seal Replace fire ring seal
Stuck or damaged linkage-governor,
wastegate, compressor bypass Repair or replace

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Pre-chamber system fault Check system
Insufficient fuel supply Check gas pressure
Engine will not reach rated speed
Dirty intake air filters Clean or replace
Control faults See ESM FAULT CODES
Check pre-chamber pressure
Engine cannot make rapid load changes Pre-chamber system fault regulator and sensing lines
Control faults See ESM FAULT CODES

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Driven equipment loading scheme is Review the loading profile of the

more than the engine can accept driven equipment and adjust.

  Engine misfires at light load Sticky gas admission valve causing

Repair or replace gas admission
engine misfire Worn or faulty spark
valve(s)
plug causing engine misfire
Worn or faulty spark plug
Clean or replace spark plug(s)
causing engine misfire

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Sticky gas admission valve causing

Repair or replace gas admission valve(s)
engine misfire
Worn or faulty spark plug causing
Clean or replace spark plug(s)
engine misfire
Insufficient fuel supply Check gas pressure
Engine will not run at Dirty intake air filters Clean or replace
maximum power Clogged/dirty intercooler (air side) Remove and clean
Air leaks in intake system Find and correct as required
Leaking exhaust/intake valve Repair, replace or overhaul as required
Control faults See ESM FAULT CODES

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Locate and correct leak. Excessive
Exhaust bellows leak causes discoloration of exhaust insulation may
low reserve help find the leak.

Engine speed is unstable

MAS Valve is closed too far. Stepper Turn MAS counterclockwise to open
position is well above 1400 steps near setting until stepper is 1200±200 steps at
full load. 100% torque.
Excessive valve clearance Adjust to specification
Knocking or unusual noises Sticking valves or rocker arms Repair or replace
Other mechanical damage Inspect and repair

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Engine Troubleshooting
SYMPTOM PROBABLE CAUSE REMEDY

Gas admission valve sticking, causing Repair or replace gas admission valve(s)
engine misfire
Emission levels too high
Leaking exhaust/intake valve Repair, replace or overhaul as required
Control faults See ESM FAULT CODES
Insufficient oil Add oil as required
Oil filters plugged Change elements
Clean and polish valve, clean sensing lines Reset
Oil pressure regulating valve faulty regulated oil pressure at rated speed and oil
Low or fluctuating oil pressure temperature
Determine and correct source of dilution
Oil dilution
Change oil and filter elements
Check for coolant leaks into oil .Correct source
Oil foaming
of foaming and repair any resulting damage

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Insufficient fuel supply Check gas pressure
Low gas/air pressure Faulty gas regulator Repair or replace
Control faults See ESM FAULT CODES
High gas/air pressure Excessive line pressure Reduce line pressure
Low coolant level Fill cooling system
  Low jacket coolant pressure
Pump cavitation Remedy source of cavitation

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Raise expansion tank to provide proper
Low pressure to jacket or Insufficient expansion tank height
pressure to pump inlet
auxiliary coolant
Orifice all air bleeds to expansion tank from
pump/pump cavitation Oversize air bleeds
engine, cooler, and piping to 0.25" or less
Misadjusted oil pressure Readjust regulating valve to proper
regulating valve pressure at operating temperature
High oil pressure Low oil temperature Allow engine to warm up
Inspect/replace lube oil thermostat elements
Oil pressure regulating valve
stuck in closed position Repair or replace valve

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Inspect/replace jacket water
Faulty thermostats
thermostat elements
Low jacket coolant Low load Increase load
temperature
Reduce radiator fan speed or block air flow as
Low ambient air temperature
required
Low coolant level Fill cooling system
Air bound cooling system Purge air from cooling system Clear vent lines
High jacket coolant Poor coolant circulation Check water pumps, piping and coolers
temperature
Inspect/replace jacket water thermostat
Faulty thermostats
elements

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Engine Troubleshooting
SYMPTOM PROBABLE CAUSE REMEDY
Oil leaks Locate and repair leaks
High crankcase vacuum Readjust breather system
High oil consumption
1.Determine source of wear
Worn piston rings/liners
2.Repair and replace as required
Leaking igniter sleeves
1.Determine and correct source
Leaking valve seats 2.Change oil and filters
Oil contamination with
water or glycol Leaking cylinder sleeve seals
Leaking water pump that will leak
Rebuild or replace water pump
into sump
Leaking air inlet system Determine and correct source of air leak
Oil contamination with
silicon Dirt in fuel line Find source and correct

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Engine Troubleshooting
SYMPTOM PROBABLE CAUSE REMEDY
Oil contamination with Rapid engine wear or component
Determine cause and correct damage
wear metals failure
Check alignment and crankcase deflection
Loose foundation bolts
Excessive vibration Torque bolts to specification
Coupling alignment Correct alignment
Low pressure to jacket or auxiliary See “Low pressure to jacket or auxiliary
coolant pump.Pump cavitation low coolant pump/pump cavitation”
auxiliary coolant flow troubleshooting
Dirty oil cooler Clean oil cooler
High oil temperature
Inspect/replace lube oil cooler thermostat
Faulty thermostats
elements
High auxiliary coolant temperature Determine and correct cause of high auxiliary
coolant temperature

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Engine Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY

Low coolant level Fill cooling system

High oil temperature Air bound cooling system Purge air from cooling system Clear vent lines
Poor coolant circulation Check water pumps, piping and coolers
Excessive fuel consumption Leaks in fuel system Repair as required
Turbocharger: Excessive noise Turbocharger bearing damage Inspect and repair
or vibration Control faults See ESM FAULT CODES
No 24V power or ground to HMI See E-Help HMI blank
HMI overheated 75°C (167°F) Move HMI to cooler location
HMI Screen is blank
Turn the backlight to maximum brightness for
HMI is too cold <-25° (-13°F)
operation down to -40°

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
Check for Loose Connection
Between ECU and Sensor
FAULT CONDITIN Remedy :2
OIL PRESS
Inspect Sensor and Connectors
PROBABLE CAUSE
for Damage
This fault means that the Remedy:3
signal being received by Check Continuity Between ECU
ALARM FAULT CODE: the ECU is out-of-range and Sensor
ALM211 Remedy :4
from normal operation
and is either in an OC Check Continuity Between ECU
(Open Circuit), SC (Short and Interconnect
DESCRIPTION Circuit), SH (Scale High), Remedy :5
Oil pressure sensor/wiring fault or SL (Scale Low). Check Continuity Between
Interconnect and Sensor
Remedy :6
Check for +5V at Sensor
Connector

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
Check for Loose Connection
Between ECU and Sensor
FAULT CONDITIN
IMAP LB/BK Remedy :2
  Inspect Sensor and Connectors
PROBABLE CAUSE for Damage
This fault means that Remedy:3
the signal being received Check Continuity Between
by the ECU is out-of- ECU and Sensor
ALARM FAULT CODE:
ALM212 range from normal Remedy :4
operation and is either Check Continuity Between
in an OC (Open Circuit), ECU and Interconnect
DESCRIPTION SC (Short Circuit), SH Remedy :5
Intake manifold pressure (Scale High), or SL (Scale Check Continuity Between
sensor/wiring fault Low). Interconnect and Sensor
Remedy :6
Check for +5V at Sensor
Connector

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
Check for Loose Connection
FAULT CONDITIN Between ECU and Sensor
OIL TEMP Remedy :2
  Inspect Sensor and Connectors for
PROBABLE CAUSE
Damage
This fault means that the
Remedy:3
signal being received by
Check Continuity Between ECU
ALARM FAULT CODE: the ECU is out-of-range
ALM213 and Sensor
from normal operation
Remedy :4
and is either in an OC
Check Continuity Between ECU
(Open Circuit), SC (Short
DESCRIPTION and Interconnect
Circuit), SH (Scale High),
Oil temperature sensor/wiring Remedy :5
fault or SL (Scale Low).
Check Continuity Between
Interconnect and Sensor
Remedy :6
Check for +5V at Sensor Connector

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
Check for Loose Connection
Between ECU and Sensor
FAULT CONDITIN Remedy :2
IMAP RB/FT  Inspect Sensor and Connectors
PROBABLE CAUSE for Damage
This fault means that the Remedy:3
signal being received by Check Continuity Between ECU
ALARM FAULT CODE: the ECU is out-of-range and Sensor
ALM214 from normal operation Remedy :4
and is either in an OC Check Continuity Between ECU
(Open Circuit), SC (Short and Interconnect
DESCRIPTION Circuit), SH (Scale High), Remedy :5
Right bank intake manifold or SL (Scale Low). Check Continuity Between
pressure sensor/wiring fault Interconnect and Sensor
Remedy :6
Check for +5V at Sensor
Connector

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
Check for Loose Connection
PROBABLE CAUSE Between ECU and Sensor
FAULT CONDITIN This fault means that
BOOST PRESS  Remedy :2
the signal being Inspect Sensor and
received by the ECU is Connectors for Damage
ALARM FAULT CODE: out-of-range from
ALM215 Remedy:3
normal operation and Check Continuity Between
is either in an OC ECU and Sensor
(Open Circuit), SC Remedy :4
DESCRIPTION (Short Circuit), SH Check for +5V at Sensor
Boost Pressure (Scale High), or SL
sensor/wiring fault Connector
(Scale Low).

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
Check for Loose Connection
Between ECU and Sensor
FAULT CONDITIN Remedy :2
IMAT  PROBABLE CAUSE Inspect Sensor and Connectors for
This fault means that the Damage
signal being received by Remedy:3
the ECU is out-of-range Verify Sensor Resistance
ALARM FAULT CODE: from normal operation
ALM221 Remedy :4
and is either in an OC Check Continuity Between ECU
(Open Circuit), SC (Short and Sensor
Circuit), SH (Scale High), Remedy :5
DESCRIPTION or SL (Scale Low). Check Continuity Between ECU
Intake manifold air temperature
sensor/ wiring fault and Interconnect
Remedy :6
Check Continuity Between
Interconnect and Sensor

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Remedy :1
MAIN FUEL VALVE Verify Fuel Valve Location Within
Waukesha Engine Specification
Remedy :2
Check LED in Power Distribution
Junction Box
PROBABLE CAUSE
ALM222 may be Remedy:3
caused by a main fuel Check for Contaminated, Blocked, or
valve that is stuck Stuck Fuel Valve
ALARM FAULT CODE: open or by driven Remedy :4
ALM222 DESCRIPTION equipment rotating Check Fuel Valve Wiring
Leaking main gas shutoff the engine. Remedy :5
valve/engine failed to stop in a Check for Short to Power in E-Stop
timely fashion
Harness
Remedy :6
Check for Short to Power in
Distribution #1 Harness
Remedy :7
Check for Short to Power in ECU
Harness

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
LOW OIL PRESS
PROBABLE CAUSE Remedy :1
Verify Set points Are Correct in
The oil pressure signal is below
ESP
ESM preset detection limits.
Remedy :2
ALM223 is probably the result
ALARM FAULT CODE: Verify Actual Oil Pressure
ALM223 of an engine hardware fault or
Reading
a damaged oil pressure sensor.
Remedy:3
DESCRIPTION Check for Faulty Oil Pressure
ALM223 indicates that ESM has
detected a low oil pressure state Sensor
in the engine

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
FAULT CONDITIN Check for Loose Connection
Between ECU and Sensor
KNOCK SENS Remedy :2
Inspect Sensor and Connectors
PROBABLE CAUSE
for Damage
This fault means that the signal Remedy:3
being received by the ECU is Inspect Sensor
ALARM FAULT CODE: out-of-range from normal
ALM225 Remedy :4
operation and is either in an Check Continuity Between ECU
DESCRIPTION OC (Open Circuit) or SC (Short and Sensor
ALM225 indicates that ESM has Circuit). Remedy :5
detected a problem with a Check Continuity Between ECU
specific knock sensor(Knock no
1 to 16 ) or its wiring. and Interconnect
Remedy :6
Check Continuity Between
Interconnect and Sensor

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ESM Alarm Codes, Probable Cause and Remedy

If High Voltage or No spark then
Remedy :1 If Primary fault state then
FAULT CONDITIN
Inspect Spark Plug Remedy :1
Sequentially IGN 1ST CYL Check for Loose Connection
Remedy :2
to 16TH CYL Between IPM-D and Ignition Coil
Check Spark Plug Gap
Remedy:3 Remedy :2
Replace Spark Plug Measure Ignition Coil Primary
ALARM FAULT CODE: Resistance
If Low Voltage then Remedy:3
ALM232,ALM233,ALM234,AL DESCRIPTION
This alarm indicates that the ESM Remedy :1 Check Continuity Between IPM-D
M235,ALM241,ALM242,ALM Verify Ignition Coil Secondary Resistance
system has detected a problem and Wire way Connector
243,ALM244,ALM245,ALM25 with the indicated cylinder's Remedy :2
1,ALM252,ALM253,ALM254, Remedy :4
ignition system Inspect Spark Plug Extension
ALM255,ALM311 Check Continuity Between IPM-D
Remedy:3 and Interconnect
PROBABLE CAUSE Replace Spark Plug Extension Remedy :5
This alarm means that the Remedy :4 Check Continuity Between
signal being received by the Inspect Spark Plug Interconnect and Wire way
ECU is out of range from normal Remedy :5 Connector
operation and is either in a High Check Spark Plug Gap
Voltage, Low Voltage, No Spark, Remedy :6
or Primary Fault state. Replace Spark Plug

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
FAULT CONDITIN PROBABLE CAUSE Continue operating within the
OVERLOAD ALM312 can be the result of too allowable overload up to the
much load applied to the time allowed per the engine
engine, excessive intake application (typically 2 hours in
manifold pressure, 24 hours).
ALARM FAULT environmental conditions, or an Remedy :2
CODE:312 incorrectly programmed WKI Reduce Engine Load
DESCRIPTION value. Depending on the Remedy:3
ALM312 indicates that the application, the overload Check for Excessive Intake
engine is operating above the Manifold Pressure
allowable load condition may be acceptable
Remedy :4
Verify WKI Is Programmed
Correctly in ESP

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN If Cylinder low or High then

IGN FLT Remedy :1
Determine Faulty Cylinder
PROBABLE CAUSE
Remedy :2
ALM313 results from the signal Inspect Spark Plug
being received by the ECU Remedy:3
being out of range from normal Inspect Spark Plug Extension
ALARM FAULT CODE: operation. The out-of-range
ALM313 Remedy :4
DESCRIPTION signal is due to a spark plug or
ALM313 indicates that one or Measure Ignition Coil Secondary
more cylinder's spark ignition coil that is wearing out Resistance
reference number is much faster than the others on the Remedy :5
higher or lower than the engine. The signal is either in a Measure Ignition Coil Primary
average of all the cylinders CYL HIGH (cylinder high) or CYL Resistance
LOW (cylinder low) state Remedy:6
Perform a Compression Check

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ESM Alarm Codes, Probable Cause and Remedy

Remedy :1
FAULT CONDITIN
Verify Auxiliary Water Coolant Level
HIGH INTAKE TEMP PROBABLE CAUSE Remedy :2
•Low auxiliary water coolant level Verify Auxiliary Water Cooling System
•Air lock in auxiliary water cooling Does Not Have an Air Lock
circuit Remedy:3
•Engine overload Check Balance(Static) and Vent Lines
•Faulty thermostats Remedy :4
DESCRIPTION •Faulty auxiliary water pump Inspect Auxiliary Water Cooling System
ALARM ALM315 indicates the air
FAULT •Auxiliary water radiator or cooler Remedy :5
temperature in the intake
CODE: manifold is too hot. If the air fouling Verify Engine is Not Overloaded
ALM315 temperature in the intake •Incorrect coolant mixture Remedy:6
manifold continues to rise, •Incorrectly sized auxiliary water Inspect Auxiliary Water Radiator or
the engine will shut down to radiator or cooler for local ambient Cooler
prevent engine damage and conditions Remedy:7
will activate ESD315
•Insufficient air flow through Inspect Auxiliary Water Pump
radiator Remedy:8
•Hot air recirculation around Verify Auxiliary Water System's
radiator Thermostats Are Operating Properly
•High ambient air temperature Remedy:9
•Water pump out of adjustment (if Check for Leaking Intake Valves
applicable)
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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Probable Cause: Remedy :1

Heater Block HEATER BLOCK LB Allow Enough Time for Heater Blocks to
Warm Up
The heater block temperature sensor indicates Remedy :2
a value below the calibrated limit due to sensor Check for Other Temperature Sensor
malfunction or a wiring fault. Faults
HEATER BLOCK LB TEMP HI Remedy:3
DESCRIPTION The heater block temperature sensor has Check for Mechanical Problems
ALARM ALM321 may indicate that a
FAULT exceeded the set limit for correct or safe Remedy :4
fault has occurred in the lean Check for Loose Connections
CODE: burn heater block. The lean operation of the heater block control. This could
ALM321 burn heater block houses two be a result of either a mechanical or electrical Remedy :5
cartridge type heaters used to malfunction. Check Heater Cartridge Voltage
provide a stable temperature Remedy:6
for proper operation of the HEATER BLOCK LB TEMP LOW
Check Continuity between Power
lean burn O2 sensors The heater block temperature sensor has gone Distribution #1 Connector and Heater
below the set limit for correct operation of the Cartridge
heater block control. This could be a result of Remedy:7
either a mechanical or electrical malfunction. Check Continuity Between AFPM and
ECU

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Remedy 1:

CALIBRATE ACT Perform Manual Actuator Calibration
1. Turn on power to Power
Distribution Junction Box.
2. Using ESP, go to [F4] Governor
Probable Cause: screen and initiate a "Manual
Actuator Calibration".
ALARM ALM322 is probably the result of
DESCRIPTION 3. While actuator is being calibrated,
FAULT ALM322 indicates invalid data invalid data in NVRAM internal to
CODE: watch actuator to verify lever
was found when reading ECU. This alarm becomes active on a
ALM322 moves throughout its entire range.
actuator feedback new ECU installation as there is no • 50% – 0% large steps
information from memory data available for the actuator as it
internal to the ECU. has never been calibrated. • 50% – 100% large steps

• 50% – 100% small steps

• 50% – 0% small steps

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Remedy 1:

STUCK THROT LINK Check Actuator Travel
Probable Cause:
ALM323 STUCK THROTTLE LINK: is
Remedy 2:
probably the result of the throttle
Perform Manual Actuator Calibration
linkage binding up for part or all of
DESCRIPTION its travel.
ALARM ALM323 indicates the throttle ALM323 STUCK THROTTLE LINK DIF:
FAULT linkage was determined to be
CODE: stuck because the range Indicates that the position feedback
ALM323 between the minimum and difference is too far away from
the maximum feedback what the ESM is commanding the
values was smaller than actuator, but the actuator
expected, or the actual and differential is constant. Most likely
desired position varied by
more than the calibrated due to an actuator needing to have
amount. a manual calibration to correct the
position discrepancy, or something
is causing the throttle linkage to
bind.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
STUCK WG LINK Probable Cause:
ALM324 STUCK WGATE LINK: is
probably the result of the
wastegate linkage binding up for Remedy 1:
DESCRIPTION part or all of its travel.
ALM324 indicates the Check Valve Plate For Seizure or Binding
ALARM ALM324 STUCK WGATE LINK DIF:
FAULT wastegate linkage was
CODE: determined to be stuck Indicates that the position Remedy 2:
ALM324 because the range between feedback difference is too far away Run Manual Actuator Calibration
the minimum and the from what the ESM is commanding
maximum feedback values the actuator, but the actuator
was smaller than expected, or
the actual and desired differential is constant. Most likely
position varied by more than due to an actuator needing to have
the calibrated amount. a manual calibration to correct the
position discrepancy, or something
is causing the wastegate linkage to
bind

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Probable Cause:
FAULT CONDITIN
Two fault conditions will generate
STUCK BYP LINK alarm code ALM325, either FB
(Feedback) or  DIF (Differential):
FB:  Feedback indicates that the
position feedback from the actuator is
not changing when compared to that Remedy 1:
which the ESM is commanding the Check Valve Plate For Seizure or Binding.
ALARM
FAULT valve.  Most likely due to the valve
CODE: DESCRIPTION plate being bound or seized. Remedy 2:
ALM325 ALM325 indicates there is a   Run Manual Actuator Calibration
problem with the feedback
position from the bypass DIF: Differential indicates that the
valve Actuator position feedback difference is too far
away from what the ESM is
commanding the valve but the valve
differential is constant.  Most likely
due to an actuator needing to have a
manual actuator calibration to correct
the position discrepancy or something
is causing the actuators plate to bind.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
IGN COM FAULT
Remedy 1:
Check for Loose Connections.

Remedy 2:
Probable Cause:
ALARM FAULT Check for Damaged Connectors.
DESCRIPTION ALM332 is the result of a
CODE: ALM332 indicates there is a
ALM332 disconnected or damaged
communication problem Remedy 3:
CAN bus harness.
between the IPM-D and the Check Resistance of Termination Resistors.
ECU.
Remedy 4:
Check Continuity of CAN Harness.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Remedy 1:
HIGH COOLANT Verify Auxiliary Water Coolant Level
TEMP Probable Cause: Remedy 2:
Engine overheating has many causes: Verify Auxiliary Water Cooling System
1)Low auxiliary water coolant level Does Not Have an Air Lock
2)Air lock in auxiliary water cooling Remedy 3:
circuit Check Balance(Static) and Vent Lines
3)Engine overload Remedy 4:
DESCRIPTION 4)Faulty thermostats Inspect Auxiliary Water Cooling System
ALARM ALM333 indicates that the
FAULT 5)Faulty auxiliary water pump Remedy 5:
engine is overheating. If the 6)Auxiliary water radiator or cooler
CODE: coolant temperature Verify Engine is Not Overloaded
ALM333 continues to rise, the engine fouling Remedy 6:
will shut down to prevent 7)Incorrect coolant mixture Inspect Auxiliary Water Radiator or Cooler
engine damage and will 8)Incorrectly sized auxiliary water Remedy 7:
activate an ESD333. radiator or cooler for local ambient Inspect Auxiliary Water Pump
conditions Remedy 8:
9)Insufficient air flow through Verify Auxiliary Water System's
radiator Thermostats Are Operating Properly
10)Hot air recirculation around Remedy 9:
radiator Check for Leaking Intake Valves
11)High ambient air temperature
Water pump out of adjustment (if
applicable) BANGLADESH GAS FIELDS COMPANY LIMITED
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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
WIDE OPEN Probable Cause:
THROTTLE Wide Open Throttle has many probable Remedy 1:
causes; the most common are: Check for Intake Restriction
1) Excessive intake restriction, including Remedy 2:
plugged or dirty air filters Locate and Correct Source of Mechanical
2) Throttle linkage worn or out of Failure
ALARM DESCRIPTION adjustment
FAULT Remedy 3:
ALM334 indicates that the 3) Engine misfire
CODE: throttle actuator has been Check Linkage for Seizure or Binding
ALM334 open to 100% for a 4) Excessive load on startup Remedy 4:
predetermined amount of 5) Low fuel pressure Run Manual Actuator Calibration
time. This is most likely due 6) Excessively lean or rich condition Remedy 5:
to a mechanical problem. 7) Poor fuel quality Cycle Power to Actuator and Calibrate
8) Misadjusted or malfunctioning
wastegates
9) Turbocharger malfunction
10) Excessive exhaust backpressure

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Remedy 1:

HIGH OIL TEMP Verify Auxiliary Water Coolant Level
Remedy 2:
Verify Auxiliary Water Cooling System Does
DESCRIPTION Not Have an Air Lock
ALM335 indicates that ESM Remedy 3:
has detected a fault with the Probable Cause: Check Balance(Static) and Vent Lines
signal from the oil The oil temperature signal is Remedy 4:
ALARM temperature sensor. The fault above ESM preset detection
FAULT is triggered when the Inspect Auxiliary Water Cooling System
CODE: limits. ALM335 is probably Remedy 5:
temperature signal from the the result of an unsafe engine
ALM335 sensor is observed by the ECU Verify Engine Is Not Overloaded
to be above a threshold set- operating condition or a Remedy 6:
point and means that the oil damaged temperature sensor Inspect Auxiliary Water Radiator or Cooler
temperature may be above Remedy 7:
normal operating conditions.
Inspect Auxiliary Water Pump
Remedy 8:
Verify Auxiliary Water System's Thermostats
are Operating Properly

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
FUEL RAIL PRESS
DESCRIPTION
ALM352 indicates that ESM Remedy 1:
has detected a problem with
ALARM Check for Loose Connection Between ECU
the fuel pressure sensor or Probable Cause:
FAULT wiring. When this fault and Sensor
Four fault conditions will Remedy 2:
CODE: occurs, ESM will run with a
ALM352 default value in place of the generate alarm code ALM352: Inspect Sensor and Connectors for Damage
actual sensor reading, but will OC (Open Circuit), SC (Short
Remedy 3:
trigger the alarm to notify the Circuit), SH (Scale High), and SL
Check Continuity Between ECU and Sensor
operator of the condition. (Scale Low). Remedy 4:
Check for +5V at Sensor Connector

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
HIGH IGN PWR
Remedy 1:
View the [F10] Status Panel in ESP.
DESCRIPTION Click  "View Faults" button.
ALM353 occurs when the Look for an active HIGH VOLT and/or NO
ignition energy level is at Probable Cause:
ALARM SPARK alarm. Continue troubleshooting by
Level 2 (highest level). This ALM353 is triggered by other
FAULT clicking on alarm code from below.
CODE: alarm serves as a warning to alarms. Both the HIGH VOLT
ALM353 an operator that at least one and NO SPARK alarms for all
spark plug on the engine is ALARM FAULT CODE:
individual cylinders will
getting worn and should be ALM231,ALM232,ALM233,ALM234,ALM235,A
replaced. trigger ALM353.
LM241,ALM242,ALM243,ALM244,ALM245,AL
M251,ALM252,ALM253,ALM254,ALM255,AL
M311

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
HT COOLANT PRESS

Remedy 1:
DESCRIPTION Check for Loose Connection Between ECU
Probable Cause:
ALM355 indicates that ESM has and Sensor
ALARM Four fault conditions will
detected a problem with the HT Remedy 2:
FAULT generate alarm code
CODE: coolant pressure sensor or wiring. Inspect Sensor and Connectors for Damage
ALM355: OC (Open
ALM355 When this fault occurs, ESM will Remedy 3:
Circuit), SC (Short
run with a default value in place Check Continuity Between ECU and Sensor
Circuit), SH (Scale High),
of the actual sensor reading, but Remedy 4:
and SL (Scale Low).
will trigger the alarm to notify the Check for +5V at Sensor Connector
operator of the condition.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
COOLANT TEMP
DESCRIPTION
ALM422 indicates that ESM has
detected a problem with the
coolant temperature signal Probable Cause: Remedy 1:
ALARM from the coolant temperature This fault means that the Check for Loose Connection Between ECU and
FAULT sensor. When this fault occurs, signal being received by the Sensor
CODE: ESM will run with a default
value in place of the actual ECU is out-of-range from Remedy 2:
ALM422 normal operation and is Inspect Sensor and Connectors for Damage
sensor reading, but will trigger
the alarm to notify the operator either in an OC (Open Remedy 3:
of the condition Circuit), SC (Short Circuit), SH Check Continuity Between ECU and Sensor
(Scale High), or SL (Scale Remedy 4:
Low). Check Continuity Between ECU and Sensor

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
Remedy 1
OIL PREFILTER
PRESS Check for Loose Connection Between ECU
and Sensor
DESCRIPTION Remedy 2
ALM433 indicates that ESM Probable Cause: Inspect Sensor and Connectors for Damage
ALARM has detected a problem with Remedy 3
This fault means that the
FAULT the oil pre-filter pressure
CODE: sensor or wiring. When this signal being received by the Check Continuity Between ECU and Sensor
ALM433 fault occurs, ESM will run with ECU is out-of-range from Remedy 4
a default value in place of the normal operation and is Check Continuity Between ECU and
actual sensor reading, but will either in an OC (Open Interconnect
trigger the alarm to notify the Circuit), SC (Short Circuit), SH Remedy 5
operator of the condition
(Scale High), or SL (Scale Check Continuity Between Interconnect and
Low). Sensor
Remedy 6
Check for +5V at Sensor Connector

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
CAN BUS ERROR

DESCRIPTION Remedy 1
ALM435 indicates that ESM Check CAN bus Connections
has detected a problem with Probable Cause: Steps are
ALARM the CAN bus. It's possible to ALM435 can occur from 1) Disconnect each CAN harness connector
FAULT have a small number of these message overruns,
CODE: occur during the life cycle of and inspect for damage.
ALM435 the engine; however, multiple unexpected messages, 2) Check continuity of CAN GND(1302)
faults could mean there is a unexpected interrupts, bad throughout entire CAN circuit.
larger issue. During normal shielding on CAN bus 3) Verify that all CAN bus connections are
operation, this fault should harness, or if the CAN bus connected and secure, and that no other
never occur. goes completely off. non-ESM devices are plugged into the CAN
bus.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
Remedy 1
THROTTLE
ACTUATOR Check for Loose Connection Between ECU and
Actuator
Remedy 2
Verify Power to Actuator
Probable Cause: Remedy 3
Three fault conditions will Check Continuity Between Power Distribution
generate alarm code Junction Box and Actuator
ALARM
FAULT ALM441: THROTTLE Remedy 4
DESCRIPTION Check Continuity Between Actuator and ECU
CODE: ALM441 indicates there is a ACTUATOR, OC (Open
ALM441 problem with the feedback Circuit), and SC (Short Remedy 5
from the throttle actuator. Circuit). Check Continuity Between Power Distribution
Junction Box and Interconnect
Remedy 6
Check Continuity Between Interconnect and
Actuator
Remedy 7
Check Continuity Between Actuator and ECU

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
WGATE ACTUATOR
Remedy 1
Verify Actuator Lever and Linkage Moves
Freely
ALARM Probable Cause:
DESCRIPTION Remedy 2
FAULT Three fault conditions will
CODE: ALM443 indicates there is a Check Actuator Lever and Linkage for Binding
generate alarm code ALM443:
ALM443 problem with the feedback Remedy 3
from the wastegate actuator. WGATE ACTUATOR, OC (Open
Verify Power to Actuator
Circuit), and SC (Short Circuit).
Remedy 4
Check Continuity of Actuator Harness

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
BAROMETRIC PRESS
DESCRIPTION
ALM444 indicates that ESM Remedy 1
has detected a problem with
the barometric pressure Probable Cause: Check for Loose Connection Between ECU and
ALARM sensor or its wiring. When This fault means that the signal Sensor
FAULT this fault occurs, ESM will run being received by the ECU is Remedy 2
CODE: with a default value in place out-of-range from normal Inspect Sensor and Connectors for Damage
ALM444 of the actual sensor reading, operation and is either in an OC Remedy 3
but will trigger the alarm to
notify the operator of the (Open Circuit), SC (Short Check Continuity Between ECU and Sensor
condition. Circuit), SH (Scale High), or SL Remedy 4
(Scale Low). Check for +5V at Sensor Connector

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Remedy 1

Verify Wiring Between Customer Harness and
REMOTE RPM
Remote RPM Source Is Secure
Remedy 2
Check ECU Side of Customer Harness for
DESCRIPTION
ALM451 indicates ESM has Damage
ALARM detected that the remote Remedy 3
FAULT RPM analog input is over Probable Cause: Determine Remote RPM Signal Type
CODE: the acceptable range. When
ALM451 ALM451 can be caused by Remedy 4
ALM451 is active, the engine faulty wiring or an incorrect Verify ESM Is Configured Correctly
continues to run but uses
the status of the high signal from the external Remedy 5
idle/low idle digital input control. Verify Remote RPM Signal Is in Correct Range
for engine speed setpoint. for Milliamp Input
Remedy 6
Verify Remote RPM Signal Is in Correct Range
for Voltage Input

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
BATT VOLT
DESCRIPTION Remedy 1
ALM454 indicates the ESM has detected BATTERY RECHARGING SYSTEM: If
supply voltage is out of specification.
When ALM454 is active, the engine voltage reading is lower than 21
continues to operate as long as the Probable Cause: volts or higher than 32 volts, fix
ALARM supply voltage continues to power If a battery is used to supply battery and/or recharging system.
FAULT components on the engine. For example, power to the Power Once battery and/or recharging
CODE: fuel valves typically require 18 volts to Distribution Junction Box, it is system is corrected, continue to
ALM454 open, so if the voltage falls below this
level, the engine will stop. likely that the battery and/or clear fault code.
recharging system is not Remedy 2
working correctly. If a power POWER SUPPLY: If voltage reading is
supply is used to supply lower than 21 volts or higher than
power to the junction box, 32 volts, correct incoming power
then the power supply is not supply (24 VDC nominal). Once
to specification power supply is corrected, clear
fault code.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
HIGH ECU TEMP
Remedy 1
Probable Cause: Remove Heat Source
ALM455 is caused by a 1. Locate heat source near ECU that is
source near the ECU (such as increasing ECU's temperature.
ALARM DESCRIPTION
ALM455 indicates ESM has generator cooling air 2. Remove or relocate heat source to a
FAULT
CODE: detected the ECU's internal discharge) that is emitting location that will not affect the ECU's
ALM455 temperature has increased too much heat or by temperature.
beyond the maximum insufficient ventilation 3. Wait for ECU to cool within normal
recommended operating causing the ECU to increase temperature range.
temperature. When ALM455
is active, the engine in temperature beyond 4. Once ECU cools, ALM455 will deactivate.
continues to operate. acceptable limits.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
HIGH OIL FILTER PRESS
DIFFERENTIAL
ALARM
Probable Cause:
FAULT Remedy 1
CODE: ALM511 is caused by either
ALM511 DESCRIPTION Check Oil Filters
ALM511 indicates ESM has detected the clogged oil filters, a faulty
differential pressure between the oil header sensor, or a wiring problem.
and pre-filter oil pressure sensors are above
the upper limit.

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN Probable Cause:

HIGH FUEL PRESSURE ALM512 can be caused by
incorrect gas/air pressure, Remedy 1
ALARM
FAULT DESCRIPTION gas pressure at gas train Verify Gas/Air Value
CODE: ALM512 indicates ESM has detected fuel inlet above regulator Remedy 2
ALM512 pressure in the main gas rail is above the Check Pressure at Gas Train Inlet
upper limit. In some cases, injection could specification causing poor
cease due to gas/air pressure exceeding regulation, faulty fuel Remedy 3
limits of injectors, causing engine pressure sensor/wiring, high Check for Faulty Gas Regulator
shutdown intake manifold pressure, or
faulty intake manifold
sensor/wiring..

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ESM Alarm Codes, Probable Cause and Remedy

Remedy 1
FAULT CONDITIN
Verify Inlet Pump Pressure
COOLANT PRESS LOW Remedy 2
ALARM Probable Cause: Check Engine Coolant System
FAULT
CODE: DESCRIPTION Remedy 3
ALM532 ALM532 indicates the ESM has detected ALM532 can be caused by a Inspect Balance Lines
that the high temperature coolant pressure sensor failure, pump failure, low Remedy 4
is below the alarm limit. inlet pressure, or a leak in the Check for Blocked Passages
coolant passage. Remedy 5
Inspect Water Pump

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
USER DIP
Probable Cause:
ALARM A status change has Remedy 1
FAULT occurred with a piece of Troubleshoot and Correct Fault
CODE: equipment or machinery of Customer Equipment or
ALM541 DESCRIPTION Machinery
that is connected to the
ALM541 indicates ESM has detected that ECU which uses one of the
one of the user digital inputs has gone from
low to high. four digital inputs to signal
and record the alarm

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ESM Alarm Codes, Probable Cause and Remedy

FAULT CONDITIN
START ON WITH RPM>0 Probable Cause:
Remedy 1
ALARM
FAULT The local control is erroneously Fix local control so that the start
CODE: holding the start engine digital engine digital input stays low while
ALM542 DESCRIPTION engine is running.
ALM542 indicates the ESM has detected input high while the engine is
that the start engine digital input is high for rotating.
more than a calibrated amount of time
when the engine is rotating

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ESM Alarm Codes, Probable Cause and Remedy

Remedy 1
FAULT CONDITIN Check for Loose Connection
AMBIENT TEMP Between ECU and Sensor
Probable Cause:
This fault means that the Remedy 2
ALARM Inspect Sensor and Connectors
FAULT signal being received by the
CODE: ECU is out-of-range from for Damage
ALM544 DESCRIPTION normal operation and is Remedy 3
ALM544 indicates the ESM has detected a either in an OC (Open Verify Sensor Resistance
problem with the ambient air temperature Remedy 4
signal from the ambient air temperature Circuit), SC (Short Circuit),
SH (Scale High), or SL (Scale Check Continuity Between ECU
sensor
Low). and Sensor

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ESM Alarm Codes, Probable Cause and Remedy

Remedy 1
FAULT CONDITIN
Contact your Waukesha Engine
INTERNAL FAULT Probable Cause: Distributor
ALARM Remedy 2
FAULT The ECU has experienced an Relay full fault information to your
CODE: internal error. This error can Waukesha Engine Distributor
ALM555 DESCRIPTION generally be resolved in the field. Remedy 3
ALM555 indicates that the ESM system has Follow the directions provided by
detected a possible internal ECU error. This your Waukesha Engine Distributor
error is an indication of either a calibration
or ECU problem on how to resolve the error.

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Now we are going to see

ESM Shutdown Fault Codes,
PROBABLE Cause and Remedy

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Check for Loose Connections
SHUTDOWN CONDITION
Remedy 2
CRANK MAG PICKUP Check Condition of Pickup
Probable Cause: Remedy 3
ESD212 may be the result of Check Continuity Between ECU and Pickup
SHUTDOWN debris on the crankshaft Remedy 4
magnetic pickup, a misadjusted Check Continuity Between ECU and
FAULTCODE:
DESCRIPTION pickup, or a faulty pickup or Interconnect
ALM212
ESD212 occurs when the ECU detects fewer wiring Remedy 5
crankshaft pulses between camshaft pulses than Check Continuity Between Interconnect and
it was expecting. Pickup
Remedy 6
Replace Crankshaft Magnetic Pickup

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Check for Loose Connections
SHUTDOWN CONDITION Remedy 2
CAM MAG PICKUP Check Condition of Pickup
Remedy 3
Probable Cause: Check Continuity Between ECU and Pickup
SHUTDOWN ESD214 may be the result of Remedy 4
FAULT CODE: debris on camshaft magnetic Check Continuity Between ECU and
ALM214 pickup, a misadjusted pickup, or Interconnect
DESCRIPTION a faulty pickup or wiring. Remedy 5
ESD214 occurs when too many crankshaft pulses Check Continuity Between Interconnect and
are identified between magnetic pickups (or no Pickup
magnetic pickup pulses are detected). Remedy 6
Replace Camshaft Magnetic Pickup

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ESM Shutdown Fault Codes, Probable Cause and Remedy

ProbableCause : Remedy 1
SHUTDOWN CONDITION ESD221 may be the result of the Reprogram Rotating Moment of Inertia in ESP
following: Remedy 2
OVERSPEED ENGINE Check Throttle Linkage for Free Movement and
• Throttle linkage being stuck or
misadjusted (for throttled Recalibrate Throttle Actuator
SHUTDOWN engines). (Throttled Engines Only)
• Rotating moment of inertia of Remedy 3
FAULTCODE: Verify WKI Is Programmed Correctly in ESP
ALM221 DESCRIPTION the driven equipment
ESD221 indicates that the engine was running incorrectly entered on the Remedy 4
faster than allowed. When engine overspeed is [F4] Governor panel in ESP. Verify Fuel System Is Adjusted Correctly
detected, the fuel and ignition are stopped. • Instantaneous loss of load.
• Engine setup issues.

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
SHUTDOWN CONDITION
Verify Shutdown was Intended by Customer
CUST ESD Remedy 2
Fix Customer Equipment as Required
SHUTDOWN DESCRIPTION Probable Cause: Remedy 3
ESD222 indicates that a shutdown has been ESD222 may be the result of a Check Continuity of Customer Interface Jumper
FAULT CODE:
triggered by an external action. ESM did not fault triggered by customer Harness
ALM222 initiate shutdown. When ESD222 occurs, fuel and equipment Remedy 4
ignition are stopped. This shutdown will occur Check Continuity of Customer Interface Harness
when the +24 VDC input to customer interface
harness pin 15 is removed. The input must be
held high for normal operation

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
SHUTDOWN CONDITION Since ESD223 shuts down the engine, care must
LOW OIL PRESS be taken prior to restarting engine to make sure
low oil pressure condition is not repeated.
Probable Cause:
Prior to restarting engine, consider the following:
The oil pressure signal is below
• Is there excessive oil on skid indicating oil
SHUTDOWN DESCRIPTION ESM preset detection limits.
leak?
ESD223 indicates the ESM has detected the engine ESD223 is probably the result of
FAULT CODE: • Is oil level in pan within safe operating limits?
ALM223 is in a low oil pressure state. This means that the an engine hardware fault or a
• Have oil and filters been replaced as
ECU has received a signal from the oil pressure damaged oil pressure sensor.
recommended?
sensor that is below the normal safe operating
• Has any service been performed recently that
limits of the engine and has initiated an engine
may result in low oil pressure?
shutdown.

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ESM Shutdown Fault Codes, Probable Cause and Remedy

SHUTDOWN CONDITION Remedy 1

Verify WKI Is Programmed Correctly in ESP
KNOCK Nth CYL
Remedy 2
Verify Fuel Quality Is Not Changing
Remedy 3
Verify Fuel System Is Adjusted Correctly
Probable Cause: Remedy 4
ESD224 is due to engine Verify Knock Sensor Is Installed Properly
SHUTDOWN knocking. Engine knocking can be Remedy 5
DESCRIPTION caused by an incorrectly Verify Liquids Are Not Entering Fuel Supply
FAULT CODE:
ESD224 indicates that a specific cylinder was at its programmed WKI value, a change Remedy 6
ALM224 in fuel quality, an improperly Verify Engine Is Not Overloading
maximum retarded timing due to knock. The fault
description in the fault log will indicate the installed knock sensor, or a Remedy 7
cylinder number. mechanical problem Check for Engine Mechanical Noise and
Vibrations
Remedy 8
Check for Faulty Ground Circuit
Remedy 9
Check for Spark With Timing Light

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Probable Cause: Remedy 6
SHUTDOWN CONDITIN ESD231 is probably the result of Check for Spark With Timing Light
incorrectly programmed purge time, Remedy 7
OVERCRANK
low or no crank speed, fuel supply Verify +24V at Starter Solenoid
problem, or wrong air-fuel ratio. Remedy 8
Check for Mechanical Problem
Remedy 1 Remedy 9
Verify Engine Is Cranking Properly Check for Continuity Between Power
Remedy 2 Distribution and Interconnect
Verify Correct ESP Programming Remedy 10
DESCRIPTION
SHUTDOWN Remedy 3 Check for Continuity Between Interconnect and
ESD231 indicates that the time the engine has
FAULT CODE: been cranking has exceeded the maximum Verify Power at Power Distribution Starter Solenoid
ALM231 Junction Box Remedy 11
crank time programmed in the ECU. The fault
Remedy 4 Verify Power at Fuel Valve
becomes inactive when the RPM has once again
reached zero. This fault will typically be viewed Verify +24V Starter Output at Power Remedy 12
Distribution Junction Box Verify +24V Fuel Control at Power Distribution
in the Fault History, not in Active Faults.
Remedy 5 Junction Box
Check Continuity Between ECU and Remedy 13
Power Distribution (Starter Control) Check Continuity Between ECU and Power
Distribution (Fuel Control)
Remedy 14
Check Continuity of Fuel Valve Circuit

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ESM Shutdown Fault Codes, Probable Cause and Remedy

SHUTDOWN CONDITION
ENGINE STALL
ProbableCause:
ESD232 may be the result of an Remedy 1
SHUTDOWN overload, a lack of fuel to the Verify Engine Is Receiving Fuel
DESCRIPTION engine (main or prechamber), a
FAULTCODE: ESD232 indicates that the engine stopped without fuel related problem, or a failed
ALM232 the ECU receiving a signal from a customer control crank sensor
or receiving a shutdown signal from ESM related
system components. When an engine stall is
detected, the fuel and ignition are stopped by
ESM.

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Verify "Driven Equipment ESD" Programmed
Correctly
SHUTDOWN CONDITION Probable Cause: Remedy 2
Check Local Control Panel Speed Input
OVERSPEED DRIVE EQUIP
ESD251 may be the result of the Remedy 3
user- defined overspeed limit Reprogram Rotating Moment of Inertia
SHUTDOWN Remedy 4
programming being incorrect, or
FAULTCODE: the throttle linkage being stuck or Check Throttle Linkage
ALM251 out of adjustment. (Throttled Engines Only

DESCRIPTION
ESD251 indicates that engine speed has exceeded a
user defined overspeed limit. When overspeed is
detected, the fuel and ignition are stopped.

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Reduce Engine Load
SHUTDOWN CONDITION Remedy 2
OVERLOAD ProbableCause: Check for Excessive Intake Manifold Pressure
ESD312 can be the result of too Remedy 3
much load applied to the engine, Verify WKI Is Programmed Correctly in ESP
SHUTDOWN
excessive intake manifold
FAULT CODE: DESCRIPTION pressure, environmental
ALM312 ESD312 indicates the engine is operating conditions, or an incorrectly
significantly above the allowable load. Running in programmed WKI value.
this condition is not allowed and causes the engine
to shut down.

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Probable Cause: Remedy 5

Check Continuity Between IPM- D and Yellow
SHUTDOWN CONDITION ESD313 may be the result of the Wire Tie Interconnect
E- Stop switch being pushed or an Remedy 6
LOCKOUT/IGNITION
IPM- D power problem Check 24Pin- IPMD- Connector For +24V
Remedy 7
Check Continuity Between IPM- D and
Interconnect
Remedy 1 Remedy 8
SHUTDOWN Check E- Stop Switches Check Continuity Between Interconnect and
FAULT CODE: Remedy 2 Power Distribution Junction Box
ALM313 Check for Loose Connections Remedy 9
DESCRIPTION
Remedy 3 Check for +5 Volts at ECU
ESD313 indicates the Lockout or E Stop (emergency
Check for +5 Volts at 4- Pin Remedy 10
stop) switch(es ) on the engine is pressed or there is
Interconnect Check Continuity of Left Bank E- Stop Switch
a power problem with the IPM D module (either it
Remedy 4 Harness
is not powered up or the internal fuse is blown).
Check Continuity Between 4- Pin Remedy 11
Interconnect and Yellow Wire Tie Check Continuity of Right Bank E- Stop Switch
Interconnect Harness

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Verify Auxiliary Water Coolant Level
Remedy 2
SHUTDOWN CONDITION
Verify Auxiliary Water Cooling System Does Not
HIGH IMAT ProbableCause: Have an Air Lock
High air temperature in the intake Remedy 3
manifold has many causes: Check Balance(Static) and Vent Lines
• Low auxiliary water coolant level Remedy 4
• Air lock in auxiliary water cooling Inspect Auxiliary Water Cooling System
circuit Remedy 5
• Engine overload Verify Engine is Not Overloaded
• Faulty thermostats Remedy 6
SHUTDOWN
• Faulty auxiliary water pump Inspect Auxiliary Water Radiator or Cooler
FAULTCODE: • Auxiliary water radiator or cooler Remedy 7
ALM315 fouling Inspect Auxiliary Water Pump
DESCRIPTION • Incorrect coolant mixture Remedy 8
ESD315 indicates the air temperature in • Incorrectly sized auxiliary water Verify Auxiliary Water System's Thermostats Are
the intake manifold is too hot and the Operating Properly
radiator or cooler for local ambient
engine has shut down to prevent damage conditions Remedy 9
• Insufficient air flow through radiator Check for Leaking Intake Valves
• Hot air recirculation around radiator

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Verify Auxiliary Water Coolant Level
SHUTDOWN CONDITION Remedy 2
Verify Auxiliary Water Cooling System Does Not
HIGH COOLANT TEMP Probable Cause: Have an Air Lock
Remedy 3
Engine overheating has many Check Balance(Static) and Vent Lines
causes: Remedy 4
• Low coolant level Inspect Auxiliary Water Cooling System
• Air lock in coolant Remedy 5
SHUTDOWN • Engine overload Verify Engine is Not Overloaded
FAULTCODE: • Faulty thermostats Remedy 6
ALM333 • Faulty water pump Inspect Auxiliary Water Radiator or Cooler
• Radiator or cooler fouling Remedy 7
DESCRIPTION • Incorrectly sized radiator or Inspect Auxiliary Water Pump
ESD333 indicates the engine overheated and shut cooler Remedy 8
down to prevent engine damage. Verify Auxiliary Water System's Thermostats Are
Operating Properly
Remedy 9
Check for Leaking Intake Valves

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Verify Auxiliary Water Coolant Level
SHUTDOWN CONDITION Remedy 2
HIGH OIL TEMP Verify Auxiliary Water Cooling System Does Not
Have an Air Lock
Remedy 3
Check Balance(Static) and Vent Lines
Probable Cause: Remedy 4
Inspect Auxiliary Water Cooling System
The oil temperature signal is Remedy 5
above the ESM preset detection Verify Engine Is Not Overloaded
SHUTDOWN limits. ESD424 is probably the Remedy 6
FAULTCODE: DESCRIPTION result of an unsafe engine Inspect Auxiliary Water Radiator or Cooler
ALM424 ESD424 indicates that ESM has detected a fault operating condition or a Remedy 7
with the signal from the oil temperature sensor. damaged temperature sensor. Inspect Auxiliary Water Pump
The fault is triggered when the temperature signal Remedy 8
from the sensor is observed by the ECU to be Verify Auxiliary Water System's Thermostats are
above a threshold set point, which means that the Operating Properly
oil temperature may be above normal operating
conditions.

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Probable Cause: Check Serial Cable Connection
SHUTDOWN CONDITION Remedy 2
UPDATE ERROR/FAULT ESD551 may be the result of an Verify Power Supply is Within Specification
error occurring in the download Remedy 3
SHUTDOWN of data to the ECU. This error may Verify Proper Operation of ECU by Downloading
FAULTCODE: have been due to a problem with Previous ECU Code
ALM551 the serial cable connection or
DESCRIPTION harness, or a power failure to the
ESD551 indicates that a problem occurred with an PC or ECU.
update of the ECU code

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
Verify New Calibration Was Downloaded
SHUTDOWN CONDITION
Remedy 2
SECURITY VIOLATION
Probable Cause: Verify Correct Main Engine Calibration Was
Downloaded
SHUTDOWN
FAULT CODE: DESCRIPTION The calibration downloaded to
ALM553 ESD553 indicates the engine type that is factory the ECU is of the wrong engine
coded in the ECU does not match with the type.
downloaded calibration.

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ESM Shutdown Fault Codes, Probable Cause and Remedy

Remedy 1
SHUTDOWN CONDITION Contact your Waukesha Engine Distributor
INTERNAL FAULT Remedy 2
On the Status panel, click the "View Faults"
button
Probable Cause: Remedy 3
Record all information shown on the Version
SHUTDOWN The ECU has experienced a Details screen and provide this information
FAULTCODE: serious internal error. along with the details of the calibration
ALM555 download to your Dresser Waukesha Distributor
to aid in troubleshooting.
DESCRIPTION Remedy 4
ESD555 indicates that ESM has detected a serious Follow the directions provided by your
internal ECU error. The engine cannot be run Waukesha Engine Distributor to troubleshoot
while this fault is active ECU.

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Maintenance Schedule

ITEM SERVICE AS REQUIRED 1,000 HRS. 4,000 HRS. OR 6 8,760 HRS. OR

MONTHS ANNUALLY
Air Cleaner Filter Element Check/Clean or Replace √
Air Starter Lubricator Check/Fill √
Cooling Systems Fluid Level (Jacket and
Auxiliary)
Check/Fill √
Crankcase Oil Level Check/Fill √
Spark Plugs Replace √
Pre-chamber Regulator Adjust √
Control Rod Ends and Linkage Clean/Lubricate √

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Maintenance Schedule

4,000 HRS. OR 6 8,760 HRS. OR

ITEM SERVICE AS REQUIRED 1,000 HRS.
MONTHS ANNUALLY
Engine Oil (Continuous Duty) Analyze √
NOx Sensor Check/Replace √
Spark Plugs Replace √
Valve Clearance Adjust √
Crankcase Pressure Check/Adjust √
Oil Cooler Drain √

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Maintenance Schedule

ITEM SERVICE AS REQUIRED 1,000 HRS. 4,000 HRS. OR 6 8,760 HRS. OR

MONTHS ANNUALLY
Oil Filter Elements Replace √
Admission Valve Assembly Clean or Replace √
Cooling Water Analysis Check √
Crankcase Breather Clean √
Engine Oil (Continuous Duty) Change √
Cylinder Compression/Borescope Check √
Engine Mounting and Alignment Check √

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Maintenance Schedule

ITEM SERVICE AS REQUIRED 1,000 HRS. 4,000 HRS. OR 6 8,760 HRS. OR

MONTHS ANNUALLY
Main and Rod Bearings Inspect √
Intercooler Clean and Inspect √
Cooling System (Jacket and Auxiliary) Clean and Flush √
Cooling System Thermostats Remove and Test √
Exhaust Backpressure Test √
Crankcase Pressure Relief Valves Inspect √

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Maintenance Schedule

ITEM SERVICE AS REQUIRED 1,000 HRS. 4,000 HRS. OR 6 8,760 HRS. OR

MONTHS ANNUALLY
Turbocharger Clean/Inspect √
Wastegate Vent Line Inspect/Clean √
Main Chamber Regulator Filter Replace √
Ignition Coils Inspect √
Ignition Primary Terminals, Connections,
Harness Plug and Wires Inspect √
Vibration Damper Fluid (See Note) Sample √
NOTE: For the 16V 275GL +, INNIO Waukesha recommends an initial sample at 2,000 hours after start­up. Then sample
annually after initial sample at 2,000 hours or sooner by damper manufacturer’s analysis and recommendations.

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Now we are going to see

Compressor Troubleshooting

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Compressor Troubleshooting
PROBLEM POSSIBLE CAUSE

• Oil pump pressure regulating valve set too low or sticking.

• Oil pump or oil pump drive failure.
• Oil foaming from counterweights striking oil surface (oil level
in sight glass too high), or from vortex at strainer inlet (oil level
in sight glass too low), or from leaks in pump suction line.
• Cold oil.
Low Oil Pressure • Dirty oil filter.
• Interior frame oil leaks.
• Excessive leakage at bearings.
• Improper low oil pressure switch setting.
• Oil pump relief valve set too low.
• Defective pressure gauge.
• Plugged oil sump strainer.
• Improper end clearance in oil pump

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Compressor Troubleshooting
PROBLEM POSSIBLE CAUSE

• Suction control valve malfunction.

• Faulty pressure gauges.
• Frozen/plugged inlet line.
High/Low Suction Pressure • Plugged intake screen or filter.
• Scrubber dump valve stuck open.
• Recycle malfunction.
• Site production equipment problems.
• Faulty valves or rings.
• Gas leak.
High/Low Inter-Stage Pressure • Frozen cooler section or tubing to panel.
• Faulty pressure gauges.
No multi staging • Scrubber dump valve stuck open.
• Load change.

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Compressor Troubleshooting
PROBLEM POSSIBLE CAUSE
• Loose piston.
• Piston hitting cylinder head end head or crank end head.
• Loose crosshead balance nut.
Noise in Cylinder • Broken or leaking valve(s).
• Worn or broken piston rings or wear bands.
• Valve improperly seated or damaged seat gasket.
• Liquids in cylinder
• Loose crosshead pin or pin caps.
• Loose or worn main, crankpin, or crosshead bearings.
Frame Knocks • Low oil pressure.
• Cold oil.
• Incorrect oil.
• Knock is actually from cylinder end.
• Low fluid level in damper.

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Compressor Troubleshooting
PROBLEM POSSIBLE CAUSE
• Excessive lube oil.
• Improper lube oil.
Excessive Carbon
• Oil carry-over from inlet system or previous stage.
on Valves
• Broken or leaking valves causing high temperature.
• Excessive temperature due to high pressure ratio across cylinders.

• Faulty relief valve.

Relief Valve Popping • Leaking suction valves or rings on next higher stage.
• Obstruction, closed or faulty valve in discharge line

• Excessive ratio across cylinder due to leaking inlet valves or rings on next
higher stage.
High Discharge • Fouled inter-cooler piping.
Temperature • Leaking discharge valves or piston rings.
• High inlet temperature.
• Improper lube oil and/or lube rate.

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Compressor Troubleshooting
PROBLEM POSSIBLE CAUSE
• Excessive lube oil.
• Improper lube oil.
Excessive Carbon • Oil carry-over from inlet system or previous stage.
on Valves • Broken or leaking valves causing high temperature.
• Excessive temperature due to high pressure ratio across cylinders.
• Faulty relief valve.
Relief Valve Popping • Leaking suction valves or rings on next higher stage.
• Obstruction, closed or faulty valve in discharge line
• Excessive ratio across cylinder due to leaking inlet valves or rings on next
higher stage.
High Discharge • Fouled inter-cooler piping.
Temperature • Leaking discharge valves or piston rings.
• High inlet temperature.
• Improper lube oil and/or lube rate.

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Now we will go through the

Compressor Maintenance

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Compressor Maintenance

Daily Maintenance

Check compressor frame oil level. It should be about mid-level in the sight glass and free of foam
when running. If not, determine and correct the cause. Do not overfill. Check oil makeup tank
for sufficient oil supply.
Check force feed lubricator box oil level. It should be full to the overflow line.
Log and trend piston rod packing vent/drain temperature and check distance piece vents for
leakage. If the piston rod packing vent/drain temperature is trending high, then verify leak rate
before performing maintenance.
If applicable, check suction valve unloader actuator vents for leakage.

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Compressor Maintenance

Daily Maintenance

If applicable, check head end clearance pocket vents for leakage.
Verify all cylinder high discharge gas temperature shutdowns are set to within 10% or as close as
practical above the normal operating discharge temperature. Do not exceed the maximum
discharge temperature shutdown setting for the application.
Log and trend cylinder valve cap temperatures.
Check lubricator block cycle time. See lubricator box data plate for correct cycle time. Changes in
gas composition may require a review of cycle time. Check lube sheet for units not running at
rated speed.
Check for gas, oil, and coolant leaks
Check for unusual noises or vibrations.

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Compressor Maintenance

Monthly Maintenance
Perform all Daily maintenance. Check force feed lubricator box oil level. It should be full to the
overflow line.
Verify safety shutdown functionality. If applicable, check suction valve unloader actuator vents for
leakage.
Sample compressor frame oil and send it to a reputable lubricant lab for analysis. See ER-56.06 fora
list of what an oil analysis should provide. If analysis results indicate increasing levels of lead, tin, or
copper particles in the oil, shut down unit. Remove frame top cover and crosshead guide side
covers. Visually inspect for debris. Do not disassemble further without good reason. If debris
indicates, replace affected parts, then change oil, oil filter, and clean the strainer with a suitable
solvent.
Check and log cylinder clearance devices in use and their settings

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Compressor Maintenance

Six-Month (4,000-Hour) Maintenance

Perform all Daily and Monthly maintenance. Verify safety shutdown functionality. If applicable,
check suction valve unloader actuator vents for leakage.
Shut down unit and allow sufficient time for components to cool.
Drain and replace force feed lubricator box oil.
Where applicable, clean sintered element in the small oil filter on the force feed lubrication system
now or at every main oil filter change. Use a suitable solvent. Where applicable, replace force feed
lubricator inlet filter in independent supply system.
Change compressor oil filter.
Change compressor oil. Extremely dirty environments, oil supplier recommendations, or oil analysis

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ZICOM EQUIPMENT PTE LTD
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Compressor Maintenance

Six-Month (4,000-Hour) Maintenance

results may dictate a different oil change interval. Follow these steps:
 Drain oil from frame, associated piping, and oil cooler.
 Clean oil strainer with a suitable solvent. In dry sump applications, the strainer is located
at the oil reservoir.
 Remove frame top cover and crosshead guide side covers. Visually inspect for debris. Do
not disassemble further without good reason. If debris indicates, replace affected parts,
then change the oil filter and clean the strainer with a suitable solvent.
 Refill compressor frame with fresh, clean oil.

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Compressor Maintenance

One-Year (8,000-Hour) Maintenance

Perform all Daily, Monthly, and Six-Month maintenance.

Grease VVCP stem threads at grease fitting, with 2 to 3 pumps of cylinder lube compatible grease
using a standard hand pump grease gun. Turn VVCP adjustment handle all the way in and all the
way out to lubricate the threads. Measure or count turns to return the handle to its original
position.
Open force feed lubricator box and visually inspect pump followers, cams, and gears for wear.

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Compressor Maintenance

One-Year (8,000-Hour) Maintenance

Pressure test distribution blocks.

Measure, log, and trend the following:
 Main bearing, connecting rod bearing, and crankshaft jack and thrust clearances.
 Crosshead to guide clearances.
 Piston rod runout.
If any of the above items are outside limits listed in Appendix B, find the cause and correct it. It may
require part replacement

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Compressor Maintenance

One-Year (8,000-Hour) Maintenance

Remove valves and valve gaskets:

a. Visually inspect valve pockets for damage. Verify all old valve seat gaskets are removed.
b. Have a qualified valve repair shop disassemble, visually inspect, and refurbish the valves
where needed. Provide the valve repair shop an Ariel torque chart and valve service guide.
c. Visually inspect cylinder gas passages and clean them of all debris.
If applicable, visually inspect suction valve unloader actuator stems for damage or wear. Visually
inspect stem seals for damage or wear and confirm that the actuator moves freely.

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Compressor Maintenance

One-Year (8,000-Hour) Maintenance

If applicable, visually inspect pneumatic clearance pockets for damage or wear (seating surface and
stems/stem seals). Confirm that actuator moves freely.
Inspect cylinder bores for damage or wear. Replace the cylinder body or restore the bore if any of
the following conditions exist:
 Bore surface blemishes or gouges.
 Bore out of round more than 0.001 inch per inch of bore diameter (0.001 mm/mm) or
tapered.
 Main bore is worn to counter bore diameter or larger.

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Compressor Maintenance

One-Year (8,000-Hour) Maintenance

Inspect piston rings and wear band:

 Measure and log piston ring condition, end gap, and side clearance.
 Replace rings that are damaged or outside limits listed in Appendix B.
 When replacing rings, re-measure and log ring side clearance to check for groove wear.
 Measure and log radial projection of wear band.

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Compressor Maintenance

One-Year (8,000-Hour) Maintenance

Inspect piston rods for damage and excessive wear. Replace rod if any of these conditions exist:
Gouges or scratches on the rod.
 Under size more than 0.005 inch (0.13 mm).
 Out of round more than 0.001 inch (0.03 mm).
Tapered more than 0.005 inch (0.1 mm) .
Rebuild piston rod pressure packing cases.
Re-install valves, retainers, and valve caps using new valve seat gaskets and valve cap O-rings/seals.

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Compressor Maintenance

One-Year (8,000-Hour) Maintenance

Check and re-calibrate all required instrumentation.

Clean crankcase breather filter with suitable solvent.
Check and, if needed, adjust drive chains.
If the compressor is equipped with crankcase over-pressure relief valves, visually inspect and
exercise valves to manufacturer recommendations.
Check fastener torques of gas nozzle flanges, head end head or unloader, valve caps, piston rod
packings, crosshead pin thru- bolts, crosshead guide to frame, crosshead guide to cylinder, cylinder
mounting flange to forged steel cylinder, distance piece to cylinder, distance piece to crosshead
guide, and tandem cylinder to cylinder.

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Compressor Maintenance

Two-Year (16,000-Hour) Maintenance

Perform all Daily, Monthly, Six-Month, and One-Year maintenance

Rebuild oil wiper cases.
If applicable, use new piston and stem seals to rebuild actuators on suction valve unloaders and
fixed volume pneumatic pockets. Replace piston stem assemblies where stem is damaged or worn.
Check auxiliary end chain drive for undercut sprocket teeth and chain for excessive stretching.
Replace as required.

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Compressor Maintenance

Four-Year (32,000-Hour) Maintenance

• Perform all Daily, Monthly, Six-Month, One-Year, and Two-Year maintenance.
• Remove crosshead pins. Measure and log crosshead pin to crosshead pin bore and connecting rod
bushing bore clearances. Check crosshead pin end caps and thru-bolt for wear. Replace if needed.
• Check for bushing wear in the auxiliary end drive chain tightener.
• Check for ring groove wear in pistons.

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Compressor Maintenance

Six-Year (48,000-Hour) Maintenance

Perform all Daily, Monthly, Six-Month, One-Year, Two-Year, and Three-Year maintenance
Replace lubricator distribution blocks.
Replace crosshead bushings and connecting rod bushings.
Replace connecting rod bearings.
Replace main bearings.

BANGLADESH GAS FIELDS COMPANY LIMITED