6EY18ALW

Common issues

• Injector fouling and poor spray patterns, especially when operating on HFO.
• Exhaust valve wear, burning, and seat recession, leading to loss of compression and EGT variations.
• Lube oil cooler leakage (internal or external) due to tube corrosion or gasket failure.
• Turbocharger fouling on both gas and air sides, reducing efficiency and boost pressure.
• Fuel pump element wear, affecting fuel injection timing and quantity.
• Cylinder liner wear and scuffing, particularly in the top dead center region.
• Bearing wear (main and connecting rod) indicated by abnormal noise or increased lube oil consumption.
• Charge air cooler fouling, leading to reduced engine efficiency and higher exhaust temperatures.

Inspection checklist

• Visual Inspection: Check for any oil, fuel, or water leakages from pipes, flanges, and seals. Observe general cleanliness and signs of overheating.
• Exhaust Gas Temperatures (EGTs): Monitor individual cylinder EGTs for uniformity. Significant deviations indicate injector, valve, or fuel pump issues.
• Lube Oil Pressure & Temperature: Verify within manufacturer's specified limits. Investigate any fluctuations or low pressure readings.
• Cooling Water System: Check cooling water temperatures (inlet/outlet), pressure, and expansion tank level. Inspect for leaks and signs of corrosion.
• Turbocharger Inspection: Listen for abnormal noises (whining, rubbing). Check boost pressure. Inspect air filter condition and look for oil ingress at compressor side.
• Injector Performance: Observe exhaust smoke color. A 'haze' or black smoke can indicate poor combustion or injector issues. Consider a 'cut-out' test if possible.
• Valve Gear: Listen for excessive tappet noise. If accessible, visually check valve springs for breakage and valve rotators for proper function.
• Vibration & Noise: Listen for unusual knocking, rattling, or grinding noises. Check for excessive engine vibration, which could indicate imbalance or bearing issues.
• Safety Devices: Verify functionality of overspeed trip, low lube oil pressure shutdown, and high cooling water temperature shutdown alarms/trips.
• Foundation Bolts: Visually inspect all engine foundation bolts for tightness and signs of movement or corrosion.

Service intervals

Typical wear limits

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

Critical spares

• Injector nozzles/elements and associated gaskets/seals.
• Exhaust valve spindles, seats, and guides (or complete cylinder heads).
• Fuel pump elements and delivery valves.
• Complete set of engine filters (fuel, lube oil, air).
• Turbocharger bearing cartridge or repair kit.
• Lube oil cooler tube stack or spare tubes/gaskets.
• Set of connecting rod bearings and main bearings.
• Various O-rings and gaskets for common openings (e.g., crankcase doors, inspection covers).

Safety

• High-Pressure Fuel Leaks: Risk of fire from atomized HFO spraying onto hot surfaces (exhaust manifold, turbocharger). Ensure all high-pressure fuel lines are properly shielded and double-walled where required.
• Hot Surfaces: Exhaust manifold, turbocharger, and associated piping operate at very high temperatures. Risk of severe burns. Ensure insulation is intact and warning signs are present.
• Rotating Machinery: Crankshaft, flywheel, and turbocharger rotating parts pose entanglement hazards. Ensure all guards are in place before operation.
• Pressurized Systems: Cooling water, lube oil, and starting air systems are under pressure. Improper handling during maintenance can lead to injury from sudden release.
• Electrical Hazards: High voltage from the generator (if genset) and control panel. Ensure proper lockout/tagout procedures are followed during electrical maintenance.

Class survey

During class surveys (Annual, Intermediate, Special), the surveyor will typically focus on: 1. Overall Engine Condition: General cleanliness, absence of leaks, proper securing to foundation. 2. Safety Devices: Verification of overspeed trip, low lube oil pressure shutdown, high cooling water temperature shutdown, and local/remote emergency stops. 3. Fuel Oil System Integrity: Inspection of high-pressure fuel lines, shielding, leak detection arrangements, and general fire safety measures. 4. Exhaust Gas System: Condition of exhaust piping, insulation, and spark arrestor (if fitted). 5. Crankcase Safety: Verification of crankcase relief valves and oil mist detector (if fitted) functionality. 6. Engine Performance: Review of engine logbooks, running hours, and maintenance records. May request a load test for gensets to confirm stable operation. 7. Foundation Bolts: Visual inspection for tightness and signs of movement. 8. Vibration: Assessment of abnormal vibrations during operation. 9. Cooling System: Inspection of coolers, pumps, and piping for leaks and corrosion.

Estimated lifetime: 60,000 - 80,000 hours before major engine overhaul (full strip-down and reconditioning)