6LC18

Common issues

• Fuel system issues: Clogged injectors, high-pressure fuel pump wear, or sensor failures leading to poor combustion, reduced power, or misfires. ACERT systems are sensitive to fuel quality.
• Cooling system inefficiencies: Clogged heat exchangers (jacket water, aftercooler), failing raw water pump impellers, or thermostat issues leading to overheating or reduced performance.
• Turbocharger problems: Bearing wear, impeller damage from foreign objects, or wastegate malfunctions resulting in excessive smoke, low boost pressure, or whistling noises.
• Electronic Control Module (ECM) and sensor failures: Malfunctioning sensors (e.g., oil pressure, coolant temperature, boost pressure) or ECM issues can cause derating, erratic operation, or engine shutdown.
• Exhaust system leaks or blockages: Cracks in exhaust manifolds, leaking bellows, or excessive carbon buildup in the exhaust gas passages affecting engine breathing and performance.
• Vibration and mounting issues: Worn engine mounts, misalignment with driven equipment, or internal engine imbalance causing excessive vibration and potential damage to connected systems.

Inspection checklist

• Fluid levels and condition: Check engine oil, coolant, and gear oil (if integrated) levels and inspect for contamination or unusual appearance. Look for signs of leaks around seals, gaskets, and connections.
• Fuel system integrity: Inspect fuel lines, filters, and high-pressure components for leaks, chafing, or damage. Check fuel filter differential pressure if gauges are fitted.
• Cooling system: Examine raw water strainer for cleanliness, inspect hoses for cracks/bulges, check heat exchanger end caps for leaks, and verify coolant level in expansion tank.
• Turbocharger and air intake: Check turbocharger for excessive shaft play (axial/radial), inspect air filter cleanliness, and ensure intake piping is secure and free of leaks.
• Exhaust system: Look for exhaust gas leaks, proper insulation integrity, and signs of excessive carbon buildup or corrosion.
• Belts and pulleys: Inspect V-belts for tension, cracks, and wear. Check pulleys for alignment and bearing play.
• Electrical connections and wiring: Verify all electrical connections, especially to the ECM and sensors, are secure, clean, and free from corrosion or chafing.
• Abnormal noises and vibrations: During operation, listen for unusual knocking, rattling, whistling, or grinding noises. Feel for excessive vibration at engine mounts and connected equipment.

Service intervals

Typical wear limits

Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.

Critical spares

• Complete set of fuel filters (primary and secondary)
• Engine oil filters
• Air filter element
• Raw water pump impeller kit (with gaskets/O-rings)
• Drive belts (alternator, raw water pump, etc.)
• Engine oil pressure sensor and coolant temperature sensor
• Spare set of fuel injectors (if operating in remote areas or with known fuel quality issues)
• Assortment of O-rings and gaskets for common leak points

Safety

• High-pressure fuel system: ACERT engines often utilize high-pressure common rail or unit injector systems. Leaks can create a fine mist that can penetrate skin or ignite, causing severe injury.
• Hot surfaces and rotating machinery: Exhaust manifolds, turbocharger, and rotating components (flywheel, belts) pose burn and entanglement hazards. Ensure guards are in place.
• Electrical hazards: High voltage from starter motor, alternator, and ECM wiring. Always disconnect power before working on electrical components.
• Exhaust gas leaks: Carbon monoxide (CO) and other toxic gases can be lethal in enclosed spaces. Ensure exhaust system integrity and proper ventilation.
• Emergency shutdown systems: Verify emergency stop buttons and overspeed protection systems are functional and regularly tested.

Class survey

Class surveyors will typically focus on the engine's compliance with classification society rules and statutory regulations. Key checks include: verification of engine documentation (certificates, maintenance records, logbooks), functional testing of safety devices (overspeed trip, emergency stops, low oil pressure/high temperature alarms), inspection of fuel oil and lubricating oil systems for leaks, proper pipe routing, and fire safety measures (insulation, spray shields). They will also check exhaust system integrity, engine mounting and foundation security, remote control and monitoring system functionality, and general engine room cleanliness and housekeeping. A load test or power trial may be requested to confirm engine performance and governor response, especially during initial surveys or after major repairs.

Estimated lifetime: 15,000 - 25,000 hours before major overhaul (assuming proper maintenance and operation within manufacturer's guidelines)