Safety: Unit Number: Customer: Date: Hour Meter Reading: Country: Location: Engine/Comp Model: Providence: Technician

Operation & Maintenance Management System
PM Plan: PM-GC-9000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 9000HR/1YR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 12 Hours
Unit Number: Customer: Date:

Hour Meter Reading: Country: Location:
Engine/Comp Model: Providence: Technician:
Safety
2 Complete JSA before beginning job. ☐Completed ☐N/A
Safety • Be sure to list all people working on the job.
• Make sure all hazards and special requirements are addressed.
3 Complete any required Work Permits. ☐Completed ☐N/A

Safety • Attach JSA to Work Permit and give to Safety Coordinator for approval.
• Have Tool Box Talk with Safety Coordinator and technicians involved.
• Make sure all departments in the surrounding work area are notified.
• Lock Out/Tag Out (LOTO) procedures must be documented and
followed.
4
Complete Lock Out / Tag Out procedure (LOTO). Indicate number of Number of
Safety
points locked out Lock Outs
• List the number of points a lock was applied. Example; Suction=1,
Discharge=1, Scrubber Drain=1, Fuel Gas=1, Total would be 4.
• Record count of lock points where single or group LOTO applied.
7 Is H2S known to be present on location? ☐Yes ☐No

Safety If yes, obtain current PPM level before proceeding.
Test and inspect all PPE before any work is performed. Local HSE department will PPM
assist in determining the proper PPE and special instructions.
8 Is CO2 known to be present on location? ☐Yes ☐No

Safety If yes, obtain current percentage level before proceeding.
Test and inspect all PPE before any work is performed. Local HSE department will %
assist in determining the proper PPE and special instructions.
PM-GC-9000HR-WAUK-VHP-S4-R1-20161030 Page 1 of 28
Operating Parameters
10 Record unit RPM and Overspeed setting
Running Unit overspeed setting should be set no higher than 5% over the maximum RPM Current Overspeed
of compressor frame or 5% over the maximum RPM of engine, whichever is RPM Setting
lowest.
20 Record Compressor Flow Rate (MMCFD) and Percent Recycle Valve
Running open. Discharge Fuel Gas Recycle
Inlet Meter
If unavailable note N/A Record Meter Meter Open %
In
MMCFD
25 Record process gas system pressures – inlet and discharge of all stages.
Running Record Safety Setting Low (SSL), and Safety Setting High (SSH) for each
process gas panel gauge. Suction Disch. 1 Disch. 2 Disch. 3 Disch. 4 Disch. 5
• Process gas pressure safety settings should be set so that inlet pressure Pressure
cannot approach a vacuum, no system will approach max working
pressure, and that no stage can approach max rod load. SSL
• Compressor performance programs would be an appropriate source for
determining process pressure safety settings. Special situations would SSH
require management approval.
30 Record process gas temperatures - inlet and discharge of all stages.
Running Record temperature safety settings. Cyl-1 Cyl-2 Cyl-3 Cyl-4 Cyl-5 Cyl-6
• Cylinder discharge temperature SSH's should be set at normal operating Inlet Temp
temperature plus 10%, with 350°F being the maximum allowable setting
unless approved by management. Disch. Temp
• Refer to the compressor performance program for calculated discharge
temperatures. SSH
35 Inspect inlet gas cone screen/strainer pressure drop (if equipped).

Running • Inlet gas cone screen/strainer should be monitored via differential ☐ Completed ☐ N/A
pressure each service interval. Percent Pressure Drop
• If there is excessive pressure drop, remove and clean after LOTO of Across Cone Strainer
process system
40 Record all oil pressures and their SSL's. Record all available oil
Running temperatures and their SSH's, Record all filter ΔP's.
• Refer to current OEM publications for minimum and maximum oil PSI SL Filter ∆ Temp SSH
pressure and temperature settings.
Engine Oil
• Record oil filter differential pressure (DP) if gauges are available, smaller
units are usually not equipped to read oil filter differential. Comp. Oil
• Normal oil filter DP 2-15 PSI, change oil filters if 15 psi differential
pressure.
50 Record all coolant temperatures and their SSH. Record all coolant
Running pressures and their SSL. PSI SSL Temp SSH
Refer to current OEM publications for min. and max. coolant temperatures and
safety settings Engine
Auxiliary
55 Record catalysis performance, if equipped.

Running Catalyst ☐N/A In Out SSH
• Record each cylinder exhaust temperature and the SSH, if available.
• Maximum exhaust system backpressure - 12 in. of water column at 1200
rpm, 145 BMEP (full load). Temperature
• Subtract 1 in. of water column for each 100 rpm reduction.
LB/RB DT
• Subtract 1 in. of water column for each 10 BMEP reduction.
• Do not apply these reductions beyond a minimum exhaust system
backpressure of 4 in. of water column.
• Maximum exhaust temperature variation on an engine running at 1000-
1200 rpm at 138 BMEP on natural gas fuel.
• Between cylinders on the same bank - approximately 100° F
• Maximum exhaust temperature variation between respective cylinders on
different banks (#1R versus #1L, #2R versus #2L, etc.) is approximately 50° F
Exhaust Temp Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 Cyl 7 Cyl 8 Cyl SSH Turbo SSH
Left Bank
Right Bank
60 ESM Engine Controller; Verify that each cylinder is firing. Any Issues? ☐ Issues repaired ☐ Issue need to be addressed ☐ All OK
Running Record peak spark/firing number.
Record current ignition timing. Peak Spark/Firing Number Timing BTDC
Record current WKI or Methane number (as applicable) set in controller.
• Confirm cylinders are firing by viewing the ignition control panel diagnostics
screen, and via cylinder exhaust temperature. WKI / Methane Number
• A correct WKI value must be entered into ESM and timing will be managed
through the ESM system. Refer to Waukesha Form 6295, ESM Manual
and/or Waukesha SB 11-2558E, VHP Timing.
65 Record AFR controller data (If equipped). Record target value and sensor Stepper
Running value. Record stepper position(s). Record controller gain setting. Note if Target Actual Position Gain Tracking?
controller is “Tracking” or out of range. Review, analyze and correct any
faults. Right Bank
Become familiar with current local emissions regulations. Follow compliance
Left Bank
regulations when operating and maintaining emission control systems.
70 Record intake manifold pressure from each bank.

Running PSI SSL SSH Temp SSH
• Verify that bank to bank balance is within 4” W.C.
• Record Intake Manifold Pressure, Temperature, and corresponding SSL, Single / Left
SSH’s. Bank
• Manifold Pressure Exceeding 5 PSI (40"HgA) (turbo charged engines) Engine
Right Bank
is likely to be in overload!
• Manifold Temperature Normal: Up to 10° F above design intercooler water For Dual Carbureted Engines
inlet temperature. Record DP Across Manifold
• Alarm: 15° F above design intercooler water inlet temperature.
• Shutdown: 20° F above design intercooler water inlet temperature. (normally
150° F)
75 Record bearing temperature reading and SSH (Safety Setting High) (as Highest
Running equipped Engine and/or Compressor) SSH
Temp
• Verify temperatures and trends are within limits and SSH are correctly
Engine Bearing
set. Comp. Bearing
• Maximum Main Bearing Temperature 250°F.
80 Record engine control screen shots. (ESM) Attach Screen Shots ☐Completed ☐N/A
Running
85 Review and analyze all safety settings for adequate equipment ☐Completed ☐N/A
Running protection limits.
Compare found settings to where they SHOULD be set at. Research current OEM
publications and the compressor performance program for correct settings.
90 Review and analyze alarm codes and fault history. Record any issues ☐Completed ☐N/A
Running that will need to be addressed.
100 Document all comments and issues found regarding parameters. Type comments or issues found:
Running
Visual Walk Around Inspection

110 Any oil leaks? ☐Yes ☐No
Running
120 Any coolant leaks? ☐Yes ☐No
Running
130 Any process gas leaks? ☐Yes ☐No
Running
140 Any compressor rod packing gas or oil leaks? ☐Yes ☐No
Running
150 Any issues with the condition of hoses and clamps? ☐Yes ☐No
Running
160 Any loose bolting including mounting of engine, compressor, cooler, ☐Yes ☐No
Running skid, pipe supports, flanges, etc.?
170 Any unusual noises? ☐Yes ☐No
Running
180 Any excessive or abnormal vibrations? ☐Yes ☐No
Running
199 Document all issues discovered during walk around inspection. Type comments or issues found:
Running
Temperature Checks (IR Gun)

210 Check for issues with EJW, auxiliary water, and/or compressor oil ☐Completed ☐N/A
Running thermostats.
To verify proper valve and thermostat function, obtain and analyze inlet and
outlet temperatures of each thermostatic valve housing, inlet and outlet
temperature of each system, and the temperature drop across each cooler.
220 Check compressor valve cap surface temperatures under normal ☐Yes ☐No
Running operating conditions. Are any like valves >20°F apart and/or
temperatures higher than calculated temperatures.
Like valves should be less than 20°F apart and within range of calculated
temperatures. Seek advice on tailoring valves to site-specific application when
having premature, and/ or reoccurring failures.
230 Check compressor crosshead guide surface temperatures under normal
Running operating conditions. Throw #1 #2 #3 #4 #5 #6
Reading are "surface" temperature and will vary based on load, speed, ambient,
and surface (paint, oil, dirt) conditions, however monitoring and trending will Temp.
assist in identifying potential issues prior to catastrophes.
Cross heads:
• Shoot temperature within 6" of top of guide where cross head runs
• Record reading per throw
240 Record vibration damper surface temperature (viscous type) while

Running engine is under load. Temperature
• Use extreme caution around moving components, shoot from a safe
distance.
• The surface temperature should be approx. 10-15 degrees above engine
oil temperature.
299 Document all issues discovered during temperature gun checks. Type comments or issues found:
Running
Compressor Cylinders, Packing Lubrication & Scrubber Controls

300 Record the setting of each compressor VVCP and how each cylinder is
Running loaded.
Measure in inches the distance that the pocket is opened. Cyl-1 Cyl-2 Cyl-3 Cyl-4 Cyl-5 Cyl-6
• Fully Closed = 0.0"
Cyl. Throw
• Indicate how each cylinder is loaded;
DA = Double Acted VVCP Inches
SAHE = Single Acted Head End
SACE = Single Acted Crank End Cyl. Loading
UL = Unloaded, All Suction or Discharge Valves Removed
Float = All Valves Removed
Spacers = Cylinder has Valve Spacers
Blank = No Cylinder
• The compressor performance program should be referred to often to
determine optimal VVCP settings.
310 Check all cylinder and packing lubrication. Are check valves hold or ☐Yes ☐No
Running leaking?
320 Is oil reaching the check valve from divider block? ☐Yes ☐No
Running
330 What is/are the lubrication rate(s) in seconds?
Running • Guidance: If greater than 40 seconds consult supervisor or manual RB Seconds LB Seconds
340 Any internal leakage at compressor recycle valve, dump valves, relief ☐Yes ☐No
Running valves?
Check the temperature difference between downstream vs upstream of a
particular valve to determine if leakage is occurring. Downstream side will be
cooler then upstream side.
350 Inspect scrubber dump valve controllers. Are scrubber level controllers ☐Yes ☐No
Running maintaining the appropriate level?
360 Are there any apparent worn or otherwise malfunctioning parts with ☐Yes ☐No
Running scrubber level controllers, dump valves, or site glasses?
370 Are all scrubber site glasses clean and valves are functioning? ☐Yes ☐No
Running
380 Verify correct instrument supply pressure and record reading.
Running Pressure
399 Document all discovered Cylinder lubrication and scrubber dump issues. Type comments or issues found:
Running
Miscellaneous Unit Parameters

405 Record air filter DP and inches of water column. Check air filter
Running restriction indicator.
• If air filter Δ P is excessive, replace filter element when unit is down Filter DP
Turbocharged engines require air filter change when filter Δ P > 10" H2O
• Naturally aspirated engines require air filter change when filter Δ P > 3" H2O
410 Record oil tank levels. Drain condensation from oil tank(s). ☐Full ☐3/4 ☐1/2 ☐1/4 ☐Empty
Running
Drain Condensation ☐Completed ☐N/A
415 Verify oil level controllers are functioning properly. Use dip stick when ☐Completed ☐N/A
Running applicable.
420 Record current crankcase pressure.
Inches of H2O
Running
425 Adjust crankcase pressure to 0” to -2” H₂O (if adjustable). ☐Completed ☐N/A
Running
430 Record estimated hours on engine and/or compressor oil (if NOT
Running changing this service). Engine Oil Hours Comp Oil Hours
435 Indicate oil samples were collected? ☐Engine Oil Sample collected ☐Compressor oil Sample Collected
Running Did the previous oil analysis flag any issues? ☐Yes, Issues flagged ☐No issues flagged ☐Unknown
Sample at operating temperature, using a clean sample port located upstream of, ☐Not sampled
or prior to, filtering.
440 Collect coolant sample. ☐Sample collected ☐Not Sampled
Running Sample using a clean sample port (collected every 6 months).
445 Did the previous coolant analysis flag any issues? ☐Already addressed ☐Addressing this service
Running ☐Not sampled ☐No Issues ☐Unknown
450 Inspect coolant condition and color. Mark all that apply.
Running Perform freeze point test on coolant to verify sufficient protection. ☐Good Color ☐Clean ☐Not Freeze
☐ Weak Color ☐Dirty Checked Point
455 Inspect for intercooler issues. ☐Completed ☐N/A

Running Check for coolant and/or oil in air side of cooler. Check temperature drop across
cooler.
460 Bleed air from compressor cylinder coolant jackets and oil cooler, if ☐Completed ☐N/A
Running applicable.
Indicate if checked and ok.
465 Prove governor response by upsetting linkage and examining governor ☐Completed ☐N/A
Running reaction. Check compensation setting and oil level if applicable.
470 Drain fluid from fuel filter, fuel header, and supply gas regulators. ☐Filters Drained ☐N/A
Running Verify regulators are functioning properly. Pressure Setting
Verify start gas, fuel gas, and instrument supply pressures are set at Start Supply Left “A” Regulator
correct pressure. Record pressures
Item Recommended Maximum Fuel Supply Right “A” Regulator
IR Vane Starter 150 psi 150 psi Instrument Left Power Screw
TDI Turbine Starter 40 - 150 psi 150 psi
Fuel (2nd Cut)- L5794GSI; L7044GSI 24 – 50 psi 75 psi Pre Chamber Right Power Screw
Fuel (2nd Cut) - L5794LT; L5774LT 43 – 60 psi 75 psi
Fuel “A” Reg.- GSI 4” – 5” H2O 7” H2O
Fuel “A” Reg.- LT 5.5” – 6.5” H2O 7” H2O
Instrument Gas System dependent 30-45 psi
499 Document all discovered issues with the coolant, cooling system, Type comments or issues found:
Running governor and misc. items.
Electrical Systems
500 Record alternator AMP output (if equipped).
Running Record total battery voltage (if equipped). Amps Volts ☐N/A
599 Document all discovered issues with the electrical and charging system. Type comments or issues found:
Running
Safety Shutdown and Gages

600 Prove all panel safety devices for function. ☐Completed ☐N/A
Running
610 Test all No-Flow devices. Record shut down times.
Running Looking at engine flywheel determines Left Bank (LB) & Right Bank (RB) Switch-LB Switch-RB
No. of Seconds
620 Test all oil level shut down devices.

Running Test coolant SSL. Number of Oil Level Safeties Checked
Test all scrubber SSH. Number of Coolant Level Safeties Checked
Test all vibration switches.
Number of Scrubber Level Safeties Checked
Note number of devices checked Number of Vibration Switches Checked
630 Test all ESD switches and actuators prior to start-up. ☐ Completed ☐N/A
Running Note number of devices checked. No. Devices checked
640 Verify fuel valve closes on shutdown ☐ Completed ☐N/A

Shutdown
650 Verify all process gauges return to zero once unit is blown down. ☐ Completed ☐N/A
Shutdown Calibrate all gauges found not to be correct.
660 Winterize gauge lines with anti-freeze or methanol as needed. ☐ Completed ☐N/A
Shutdown Required when ambient temperatures are near or below freezing. Winterizing
includes lines are reamed and are filled with a nonfreezing liquid.
699 Document comments and all issues found regarding process gauges. Type comments or issues found:
Shutdown
Engine Cylinder Head Compression

800 Remove cannon plug from magneto/alternator/ignition system & verify ☐ Completed ☐ N/A
Shutdown battery power is off, prior to running compression test.
Verify battery power is LOTO - This action is a safety measure to prevent flash
fires from discharging ignition.
810 Verify valve rotator function while testing compression. ☐ Completed ☐ N/A
Shutdown Mark all valve rotators with a paint stick to verify they are rotating while
conducting compression test. > A typed or written "Y" represents all rotators
functioning.
820 Record the compression pressure of each cylinder.

Shutdown • Compression tests are performed to identify head and cylinder issues.
• Test prior to adjusting valves or replacing heads, regardless of normal Left 1 Right 1
PM or Top End.
• Note - Compression test not required on overhaul. Left 2 Right 2
• With throttle wide open, crank engine minimum 100 rpm until gauge
reading stabilize. Left 3 Right 3
• Lower RPMs and/or higher altitudes will result in lower values.
Left 4 Right 4
• No cylinder should deviate more than 15 psi from average value, RUN A
WET TEST. Left 5 Right 5
• Condemning limit - 25% or 50 psi drop from new or average
Normal Range Left 6 Right 6
Model C/R Pressure (psi)
L5794LT 10.2 to 1 228 – 255 Left 7 Right 7
L5774LT 10.2 to 1 228 – 255
Left 8 Right 8
L5794GSI 8.2 to 1 177 – 198
L7044GSI 8.0 to 1 172 – 195
P9394GSI 8.0 to 1 172 – 195
898 Document comments and all issues found regarding cylinder Type comments or issues found:
Shutdown compression.
Cylinder Head Valve Recession

1025 Record current valve projection of engine valves.
Shutdown • Measure using approved tooling and methods
• Compare to previously recorded Baseline readings
• Schedule head change at 0.050”; change if exceeding 0.060”
• The acquired measurements will be utilized during sequential PM’s to establish current recession of each exhaust valve
INTAKE EXHAUST INTAKE EXHAUST

Position 1 Position 2 Position 3 Position 4 Position 1 Position 2 Position 3 Position 4
Base 1L 1R Series 4
Current 1L 1R
Recession 1L 1R
Base 2L 2R
Current 2L 2R
Recession 2L 2R
Base 3L 3R
Current 3L 3R
Recession 3L 3R
Base 4L 4R
Current 4L 4R
Recession 4L 4R
Base 5L 5R
Current 5L 5R
Recession 5L 5R
Base 6L 6R
Current 6L 6R
Recession 6L 6R
1050 Set engine cylinder head valves (Per Cylinder Method – hydraulic lifters) ☐Completed ☐N/A
Shutdown
Clearances, Torques and Firing order
Valve Valve Setting Bridge Setting Firing Order
Intake 6 Cylinder 12 Cylinder 16 Cylinder(*)
0.000” + ½ turn CW 0.000” - Flat
Exhaust 1-5-2-4-3-6 1R 6L 5R 2L 3R 4L 6R 1L 2R 5L 4R 3L R1 L1 R3 L3 R7 L7 R5 L5 R8 L8 R6 L6 R2 L2 R4 L4
Mating Cylinder 6-2-5-3-4-1 6R 1L 2R 5L 4R 3L 1R 6L 5R 2L 3R 4L R8 L8 R6 L6 R2 L2 R4 L4 R1 L1 R3 L3 R7 L7 R5 L5
1. Roll to TDC No1 R - COMPRESSION STROKE

a. Watch rocker arm assemblies of mating cylinders to determine TDC compression stroke
b. As the exhaust valves are just closing and intakes are just opening on the mating cylinder, the
cylinder is at TDC compression stroke
2. Back off pushrod adjusting screws (dead men) ½ turn (older models); Back off bridge adjusting screws ½
turn (newer models)
3. Set both bridge to valve adjusting screws to zero lash & tighten (holding bridge)
4. Set Rocker to bridge adjustment
a. Old Style - Adjust rocker to bridge screws to zero lash & tighten, then tighten pushrod adjusting
screws (dead men) ½ turn (to preload hyd. lifter)
b. New style - Adjust rocker to bridge screws to zero lash, then turn clock wise ½ turn & tighten (to
preload hyd. lifter) Series 2
5. Repeat steps 1-4 rolling CCW to each cylinder’s TDC position (set to firing order, watching mating valve)
until all valves are set (Total of two rolls of Crankshaft)
a. Usually only cylinders 1 Right & 1 Left are marked
with timing tape, the other cylinder need to watch
mating valve to determine TDC
b. Right and left sides of engine are determined by
facing flywheel.
c. Cylinders farthest from flywheel on right and left
sides are #1R and #1L cylinders, respectively.
(*) 16 cylinder - current order - change began with S/N 30688 -

always check engine nameplate.
Series 4
1070 Inspect valve cover gaskets, replace if needed (always replace on Top ☐OK- Reused ☐Replaced ☐N/A
Shutdown Ends and Overhauls when gaskets are provided in Head set).
1090 Inspect main and auxiliary water pumps (Rebuild or exchange if worn). ☐Rebuilt ☐Exchanged ☐OK – Reused ☐N/A
Shutdown
1099 Document comments and all issues found regarding Top End Task. Type comments or issues found:
Shutdown
Frame Overhaul
1510 Inspect crosshead, guide, wrist pin, Throw # 1 2 3 4 5 6
Shutdown and connecting rod areas.
Crosshead Condition G = Good / R = Replaced
Remove compressor distance piece side
Crosshead Guide Condition G = Good / R = Replaced
doors for inspections.
Crosshead Clearance Thousands of Inches (.010)
• Use a micrometer to measure.
• Document wear/condition. Crosshead Clearance within
Y = Yes / N = No
Mfg. Specifications?
• Verify weights are tight (if
applicable). Wrist Pin Condition G = Good / R = Replaced
• Replace only excessively worn Wrist Pin dimensions within
parts. Y = Yes / N = No
Mfg. Specifications?
Connecting Rod Small End
G = Good / R = Replaced
Bearing Condition
Connecting Rod large End
G = Good / R = Replaced
Bearing Condition
1530 Inspect frame running gear. ☐Completed ☐N/A
Shutdown Remove compressor top cover and visually inspect for wear metals and other issues.
• Check and adjust drive chain if required, if equipped.
• Bump and/or spot check rod bearings.
1550 Inspect all shaft seals. Replace as needed. ☐Completed ☐N/A
Shutdown Note findings and/or repairs made.
1599 Document comments and all issues found concerning frame area. Type comments o issues found:
Shutdown
Compressor Cylinders
1600 Inspect/clean all installed gas cone screens/strainers (as equipped) and Cleaned or None or
Component N/A
Shutdown inspect placement of restriction orifices. Confirmed Removed
• Inlet gas cone screen/strainer shall be remove inspect, clean and reinstall Inlet Cone Screen/Strainer ☐ ☐ ☐
• All other cone screens/strainers shall be removed at first service interval. Other Cone Screens/Strainers ☐ ☐ ☐
• If other than inlet cone strainers are installed, note location, condition, Orifices confirmed to P&ID ☐ ☐ ☐
and reasoning in comment.
• If orifices are installed, confirm size and position.
1610 Inspect corrosion coupons (if equipped). Coupon
☐N/A
Shutdown > Document observation, trend wear Measurements
1620 Remove and inspect all compressor valves. ☐Completed ☐N/A
Shutdown > Torque all valve caps. DO NOT use impacts. (Refer to Annex - Compressor Valve
Removal & Installation)
> Seek advice to tailor valves to site-specific application, when having premature
and/or reoccurring failures.
1640 If process gas is dirty, remove and inspect piston, rings, cylinder, and ☐Completed ☐N/A
Shutdown piston rod.
1. Use a micrometer to measure.
2. Document wear/condition.
3. Replace components that are worn beyond wear limits.
List worst case (Reuse all components if with-in wear limits)
1699 Document comments and all issues found with compressor cylinders and Type comments or issues found:
Shutdown components.
Fuel, Start And Governor System

1705 Visually inspect starter, if there are issues rebuild/replace as appropriate. ☐Inspect ☐Repaired ☐Replaced ☐N/A
Shutdown • Refill lubricator if equipment.
1710 Visually inspect Sealco or manual valve for damage, if equipped ☐Completed ☐N/A
Shutdown
1745 Visually Inspect throttle linkage. ☐Completed ☐N/A
Shutdown • Look for straightness and damage; inspect rod ends and ensure jam nuts
are tight
1750 Inspect all starter, fuel, and process gas hoses. Replace as needed. ☐Completed ☐N/A
Shutdown
1799 Document comments and all issues found with start, fuel, carburetor and Type comments or issues found
Shutdown governor systems.
Catalyst And Control System

1800 Clean, lubricate, and test steppers (or actuators) as applicable (if ☐Completed ☐N/A
Shutdown equipped).
• Dissemble, clean , and repair/replace as necessary
1810 Replace / Calibrate O₂ (or NOx) sensors as applicable (if equipped). ☐Replaced ☐Calibrated ☐OK ☐N/A
Shutdown • Replace Rich burn O2 sensors as prescribed by emission regulations.
• Heated Lean Burn sensors generally can be calibrated when flagged
1820 Reverse flow catalyst, if equipped. ☐Completed ☐N/A
Shutdown • Remove and reverse flow if practical.
1899 Document comments and all issues found with O2 Sensors or Catalyst. Type comments or issues found:
Shutdown
Exhaust And Air Intake Systems
1900 Check turbochargers for buildup, for signs of oil leakage, signs of cold ☐Completed ☐N/A
Shutdown housing contact and for excessive play in shaft.
If in doubt, measure play with indicator, compare to specification.
1920 Visually inspect turbo oil supply line clamps ☐Completed ☐N/A
Shutdown Supply lines will crack without clamps in place.
1930 Visually Inspect for signs of leakage at air inlet hoses, O-rings and gaskets, ☐Completed ☐N/A
Shutdown exhaust manifolds, expansion joints, exhaust collar rings, after/inner
coolers, turbo(s) and waste gates (as applicable).
Repair as needed
1999 Document comments and all issues found with turbo (and/or air intake) Type comments or issues found:
Shutdown systems.
Engine And Compressor Lube Oil

2000 Extender Series (with enlarged pan and MicroSpin filter) Oil Filters ☐Changed ☐Not Changed ☐N/A
Shutdown • Change filters every PM Lube Oil ☐Changed ☐Not Changed ☐N/A
• Change engine oil via analysis up to a maximum 0f 5000 hours
• For all other Series 4 non extenders, or if otherwise directed by Enter hours on oil
management, Change engine oil and filters on this service if NOT changed
2010 If engine is equipped, clean Microspin oil separator and change paper ☐Changed/Cleaned ☐Not Changed or Cleaned
Shutdown element.
2020 Inspect and clean engine oil system (as applicable) Mark all that apply
Shutdown • Inspect and clean the magnetic plugs in the cylinder head lube headers, (Mark just the “All Completed” if ALL applicable completed)
front and rears, and in turbo oil supply lines as equipped.
• Clean oil strainers (as equipped). All Magnets Checked & Cleaned ☐No ☐Yes
• Clean oil sump and clean pick-up screen (as equipped and accessible). Oil Strainers Checked & Cleaned ☐No ☐Yes
• Drain oil shell & tube cooler (oil tube side) or section in gas cooler. Oil Sump Checked and Cleaned ☐No ☐Yes
• Visually inspect lubrication hoses on engine. ☐All
Oil Pick-up Checked & Cleaned ☐No ☐Yes
• Inspect and clean Engine Oil Level Controller. Completed
Oil Cooler Drained ☐No ☐Yes
• Repair/Replace as needed
Lubrication hoses visually inspected ☐No ☐Yes
Le vel Controller Checked & Cleaned ☐No ☐Yes
2050 Compressor oil and filter(s). Oil Filters ☐Changed ☐Not Changed ☐N/A
• Compressor oil shall be changed when engine oil is changed Lube Oil ☐Changed ☐Not Changed ☐N/A
• If directed by management or otherwise NOT changed, indicated
hours on compressor oil at this service. Enter hours on oil
if NOT changed
2099 Document comments and all issues found regarding engine and Type comments or issues found:
Shutdown compressor oil.
Oil Supply, Air Filters And Crankcase Breathers

2100 Inspect make-up tank hoses and replace as needed. Record all issues ☐Completed ☐N/A
Shutdown found regarding oil make-up system.
2110 Clean (replace if needed) the following (AS APPLICABLE): ☐Completed ☐N/A
Shutdown • Engine crankcase breather element(s)
• Compressor crankcase breather element(s)
• Pre filter element(s)
• Air filter element(s)
Spark Plugs And Ignition System

2200 Inspect spark plugs. Clean, gap, and reuse or replace as needed. Standard
Gap Torque
Shutdown • Replace specific spark plug if defined fraught via exhaust temperatures, Plug
firing, etc. RB77CC 0.015" 35 ft. lbs.
• Clean spark plug with Actrel® 3338L dielectric solvent or compatible
solvent. Type Installed Replaced? Estimated hours if reused
• Install spark plug dry (no oil, anti-seize, or other lubricant).
• Note - Change spark plug gasket every time the plug is removed
☐Yes ☐No
2210 Address ignition system by fixing any found Magneto, wiring, or coil ☐All OK ☐Found Issues (see comments)
Shutdown issues found during running inspection
Also visually check ignition system by:
• Spot checking wiring harness for wear, nicks, cuts, & loose connections
• Spot checking high tension wiring, isolators, & caps for wear
• Spot checking coils corrosion & wear (no green stuff or cracks)
• Verifying “G” lead is attached and secure
• Address all found issues
2299 Document comments and issues found related to spark plugs and ignition Type comments or issues found:
Shutdown system.
Engine Control System

2300 Inspect integrity of "Engine Control System" wiring harnesses and wiring ☐Completed ☐N/A
Shutdown harness components (as equipped).
Visually inspect all ESM models and control system wiring
2310 Annual control system inspection (conduct as applicable) ☐Completed ☐N/A

Shutdown • Tighten all termination points in panels and at engine mounted ESD
switches.
• Inspect and clean "Engine Control System" ignition timing disk, gears,
and/or hall effect and/or mag pickups. (See annex or manual for
specifics).
• Inspect "Engine Control System" knock sensors and connectors. Check
the torque of and the connections of detonation sensors.
• Inspect "Engine Control System" detonation module and programming.
Verify all control program (Document Screen shots).
• Repair or replace as needed
Cooler And Coolant System
2400 Inspect main and auxiliary water pumps (if equipped). Inspect weep ☐Completed ☐N/A
Shutdown holes for signs of coolant leakage. Address issues if present.
2420 Is coolant analysis indicating flushing cooling system sooner than the Top ☐Yes – Flushed ☐Needs Flushing ☐Analysis states condition OK
Shutdown End/Overhaul schedule? If yes, complete the following:
• Flush system; ☐Unknown
• Inspect compressor cylinder water jackets (if applicable);
• Inspect coolant sides of oil coolers;
• Remove and inspect thermostats; replaced as required;
• Clean and check aftercooler;
• Clean & inspect cooler water sections internally;
• Charge with new fresh coolant.
2430 Check louver condition each service Louver Position:

Shutdown • Note current position of shutters ☐Condition OK ☐N/A
2440 Check cooler / radiator semiannually ☐Completed ☐N/A
Shutdown • Check for external cleanliness (cooler tubes/fins).
• Check for structural Issues
2450 Check fan and bearings annually Blade Bolt Torque

Shutdown • Check fan assembly condition, bolt torque, and pitch. Record Blade Pitch Angle
pitch/torque. ☐Blade and bearing condition OK ☐N/A
• Check bearing for wear and set screw tightness. If set screws have not
been pilot drilled, conduct.
2499 Document comments and all issues found regarding cooling systems. Type comments or i sues found:
Shutdown
Cylinder Lubrication System

2699 Document comments and all issues found with lubricator drive box, Type comments or issues found:
Shutdown lubricator pump(s), divider blocks, and no flow(s).
Alignment & Base Deflection

2500 Check and adjust engine base deflection and mounting bolt
Shutdown torque.
1R 2R 3R 4R 5R 6R 7R 8R
• Maximum Engine Base Deflection 0.002”
Coupling
• If soft foot in question on engine, check crankshaft
deflection Bolt Torque ft.lbs. BASE DEFLECTION
1L 2L 3L 4L 5L 6L 7L 8L
2510 Record engine crank deflection. (If required by above)

Shutdown
• Total of 0.0015", positive to negative, throw nearest 1 2 3 4 5 6 7 8
Front
flywheel.
• Total of 0.001", positive to negative, all other throw.
2510 Check and adjust compressor base deflection and mounting

Shutdown bolt torque.
1R 2R 3R 4R 5R 6R 7R 8R
• Maximum Engine Base Deflection 0.002”
Coupling
• If soft foot in question on engine, check crankshaft
Bolt Torque ft.lbs. BASE DEFLECTION (Mark as applicable)
deflection
1L 2L 3L 4L 5L 6L 7L 8L
2530 Check and adjust coupling alignment

Shutdown AS FOUND Rim FINAL RESULT Rim
• Align to within .005” considering 0.000 (Radial)
0.000 (Radial)
thermal growth difference of engine
and compressor.
• Record “As Found” and “As Left” 0.000 0.000
readings in thousands of inches, i.e.,
.001 Face Face
• Record Engine and Compressor thrust (Axial) (Axial)
Engine Thrust
Compressor Thrust
2540 Inspect Driver to Cooler Alignment ☐Completed ☐N/A

Shutdown Check mounting and alignment
• Inspect/ re-torque engine mount.
• Inspect sheave to sheave alignment; adjust if out of alignment
2580 Check crosshead, frame, and engine mounting bolts for tightness. Inspect ☐Completed ☐N/A
Shutdown bottle supports for correct setting. Torque distance piece support bolts.
2599 Document comments and all issues found regarding cooling systems. Type comments or i sues found:
Shutdown
Compressor Cylinder Lubricator System

2600 Inspect, clean, repair (replace as needed) lubricator system annually ☐Completed ☐N/A
Shutdown
• Remove pump and inspect cam & gear. • A generally accepted test for sufficient lubrication is to blot the
• Clean sight glass or window as applicable. rubbing surfaces with 3 or 4 layers of tissue or cigarette paper,
• Flush and refill box. immediately after removing a valve, and following a shutdown.
• Pressure test the divider blocks. • A oily discoloration through the first layer to the second tissue is
1. Pressurize the system to 3500 psi (or 10% greater than discharge
indication of proper lubrication.
pressure if discharge pressure is greater than 3500 psi).
2. If lose 1000 psi or more in 30 seconds, replace block.
3. Detail repairs in comment section.
2620 Replace no-flow batteries semiannually ☐Completed ☐N/A

Shutdown
2699 Document comments and all issues found with PSV’s and scrubber Type comments o r issues found:
Shutdown dumps.
Pressure Relief Valves (PSV), Dump Valves And Controllers

2700 Visually inspect all PSV's. ☐Completed ☐N/A
Shutdown • Verify if seal is valid (legible and not broken).
• Address issues found.
2710 Repair any faulty dump controllers, leaking dump valves, and clean any ☐Completed ☐N/A
Shutdown dirty sight glasses.
2799 Document comments and all issues found with PSV’s and scrubber Type comments o r issues found:
Shutdown dumps.
Belts, Sheaves, And Bearing Grease

2800 Inspect applicable belt condition and tension, along with respective drive Replace Adjust Need N/A OK ☐
Shutdown sheaves, replace as needed. Alternator ☐ ☐ ☐ ☐ ☐
All Applicable - OK
Cooler Drive ☐ ☐ ☐ ☐ ☐
• Properly tensioned belts will feel alive springy. Belts too tight will not Fan/Radiator ☐ ☐ ☐ ☐ ☐
deflect, loose belts feel non-reactive.
Governor ☐ ☐ ☐ ☐ ☐
• Refer to Annex “Belt Tensions or service manual for tension information
PTO Drive ☐ ☐ ☐ ☐ ☐
• Mark what belt issues were addressed and how
WP – Aux. ☐ ☐ ☐ ☐ ☐
• A single X in the “All applicable – OK” column represents all applicable
check and all OK
WP - Main ☐ ☐ ☐ ☐ ☐
Sheaves ☐ ☐ ☐ ☐ ☐
2810 Grease all applicable points as defined below. Indicate number of points Item Amount No. Points
Shutdown greased.
• Use a Lithium based grease such as Hydrotex Parasyn 70, Lithoplex® Actuator Linkage ½ -1 Pump each joint
Grease No 2, or equivalent. Alternator Idler 1- 2 Pumps
• Use High Temperature Grease on Spill Port Valves and on Linage near Aux. Water Pump 1 Pump
waste gates. Cooler Bearings 3 – 5 Pumps
• Repair any broken grease lines. Control Linkage ½ -1 Pump each joint
• Replace any non-working grease fittings. Fan Bearing (Radiator) 1- 2 Pumps
• All points grease each down service except VVCP’s Fan Idler (Radiator) 1- 2 Pumps
• VVCP need only to greased annually VVCP’s 1 Pump annually
2899 Document all discovered issues with belts, sheaves, and grease points. Type comments or issues found:
Shutdown
Startup
3000 Check battery electrolyte levels. ☐Completed ☐N/A

Shutdown Not all "maintenance free" batteries are truly maintenance free.
SAFETY NOTE: Ensure eye protection is worn when working with batteries
3010 Prepare unit for restart. (Note multiple steps!) ☐Completed ☐N/A
Starting 1. Inspect all work, remove LOTO, check for leaks, purge, pressure test system,
and close out all safety permits. Safety Note: Never address any leak under pressure! Always blow
2. Reset regulators, carburetors, steppers that were replaced or repaired to down and initiate LOTO.
previously recorded setting.
3. Check fluid levels, drain valves, make up tank valves, and process valve
positions.
4. Test engine pre-lube function. Refill lubricator
5. Test compressor pre-lube function. Refill lubricator
6. Ensure all personnel are clear.
7. Restart, check oil pressures and conduct walk around before and after
loading.
3030 Verify fuel settings RIGHT BANK (And Single Carbureted Engines)
Running RICH BURN (No AFR Controller)
Manifold Pressure
1. Verify Engine is loaded, running at a steady RPM, and fuel is at a steady state
2. Verify fuel pressure regulator settings are correct. “A” Regulator Setting
3. Verify ignition system is functioning properly - no miss-fires; engine timing Power Screw Position or Inches OUT
correct. Load Screw
MID
4. Additionally (R) | | | | | | (L) Inches
a. On dual carbureted Vee-Engines, verify banks are balanced OUT
mechanically. ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐
5. On turbocharged engines, verify that wastegate’s establish sufficient boost
(but not excessive boost) over manifold differential pressure.
6. Tune power screws (and sequentially A Regulator(s)) if needed to obtain LEFT BANK
lowest manifold pressure (Boost Method), then lean out ½” Hg per bank – Manifold Pressure
Stoichiometric setting “A” Regulator Setting
7. Record final Settings (as applicable)
RPM Power Screw Position or Inches OUT
Load Screw
Load (HP %)
MID
(R) | | | | | | (L) Inches
Bank Balance OUT
Fuel Supply PSI ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐
3035 Verify fuel settings RIGHT BANK (Or Single Carbureted Engines)
Running RICH BURN WITH AFR CONTROLLER
Manifold Pressure
1. Verify Engine is loaded, running at a steady RPM, and fuel is at a steady state
2. Verify fuel pressure regulator settings are correct. “A” Regulator Setting
3. Verify ignition system is functioning properly - no miss-fires; engine timing Power Screw Position or Inches OUT
correct. Load Screw
MID
4. Additionally (R) | | | | | | (L) Inches
a. On dual carbureted Vee engines, verify banks are balanced OUT
mechanically. ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐
b. On turbocharged engines, verify wastegate’s establish sufficient Stepper Position Range H/L
boost (but not excessive boost) over manifold differential pressure. Current O2 Value O2 Target
c. On electronically controlled engines, verify A3, ESM, CEC, or other
controller is correctly programed. LEFT BANK
5. Verify stepper motors are functioning and near mid-range Manifold Pressure
a. IF NOT tune power screws (and sequentially A Regulator(s)) if needed
“A” Regulator Setting
to center range.
6. Verify emissions using an Exhaust Gas Analyzer, gradually adjust carburetor Power Screw Position or Inches OUT
power screw to obtain desired emissions- CO, NOx, O2. Load Screw
MID
7. Verify ARF controls can “swing” to handle Fuel BTU changes (R) | | | | | | (L) Inches
8. Record final Settings (as applicable) OUT
RPM NOX PPM ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐

Load (HP %) CO2 PPM Stepper Position Range H/L
Bank Balance O2 % Current O2 Value O2 Target
Fuel Supply PSI NMHC PPM
3040 Wash unit ☐Completed ☐N/A

Running
3050 Run under load for one hour.
Running 1. Complete necessary paperwork Disc. Meter Inlet Meter Make – Up Fuel Gas
2. Verify all readings against recorded operating parameters taken before P.M. (Injection) (Tubing) (Bypass) Meter
3. Make a final inspection of unit.
4. Verify operating parameters against initial and adjusted settings. MMCFD
3099 Document final PM comments/Issues. Type comments or issues found:

Running
Document final PM comments/Issues.
Additional Materials Used Additional Comments

Qty. Part Number Description
Date & Technicians Mileage and Labor Hours

Date Technicians Working Mileage Travel Hours OT Hrs
Company Representative Estimated Totals

Customer Representative Date Totals

Safety: Unit Number: Customer: Date: Hour Meter Reading: Country: Location: Engine/Comp Model: Providence: Technician

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Operation & Maintenance Management System

Unit Number: Customer: Date:

3 Complete any required Work Permits. ☐Completed ☐N/A

7 Is H2S known to be present on location? ☐Yes ☐No

8 Is CO2 known to be present on location? ☐Yes ☐No

35 Inspect inlet gas cone screen/strainer pressure drop (if equipped).

55 Record catalysis performance, if equipped.

70 Record intake manifold pressure from each bank.

Visual Walk Around Inspection

Temperature Checks (IR Gun)

240 Record vibration damper surface temperature (viscous type) while

Compressor Cylinders, Packing Lubrication & Scrubber Controls

Miscellaneous Unit Parameters

455 Inspect for intercooler issues. ☐Completed ☐N/A

Safety Shutdown and Gages

620 Test all oil level shut down devices.

640 Verify fuel valve closes on shutdown ☐ Completed ☐N/A

Engine Cylinder Head Compression

820 Record the compression pressure of each cylinder.

Cylinder Head Valve Recession

INTAKE EXHAUST INTAKE EXHAUST

1. Roll to TDC No1 R - COMPRESSION STROKE

(*) 16 cylinder - current order - change began with S/N 30688 -

Fuel, Start And Governor System

Catalyst And Control System

Exhaust And Air Intake Systems

Engine And Compressor Lube Oil

Oil Supply, Air Filters And Crankcase Breathers

Spark Plugs And Ignition System

Engine Control System

2310 Annual control system inspection (conduct as applicable) ☐Completed ☐N/A

2430 Check louver condition each service Louver Position:

2450 Check fan and bearings annually Blade Bolt Torque

Cylinder Lubrication System

Alignment & Base Deflection

2510 Record engine crank deflection. (If required by above)

2510 Check and adjust compressor base deflection and mounting

2530 Check and adjust coupling alignment

2540 Inspect Driver to Cooler Alignment ☐Completed ☐N/A

Compressor Cylinder Lubricator System

2620 Replace no-flow batteries semiannually ☐Completed ☐N/A

Pressure Relief Valves (PSV), Dump Valves And Controllers

Belts, Sheaves, And Bearing Grease

3000 Check battery electrolyte levels. ☐Completed ☐N/A

RPM NOX PPM ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐

3040 Wash unit ☐Completed ☐N/A

3099 Document final PM comments/Issues. Type comments or issues found:

Document final PM comments/Issues.

Additional Materials Used Additional Comments

Date & Technicians Mileage and Labor Hours

Company Representative Estimated Totals

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