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GE has begun a program of re-motoring or de-rating their AC6000's for many reasons. AC6000's brand new have whats called a 7HDL engine in them. They differ greatly from the regular 7FDL in many ways. The HDL has had teething problems from day one. The original intent for the creation of the HDL was to meet new federal emissions requirements, in addition to increase potential horsepower. Here's a list of problems I have witnessed or experienced on the job - a problem with harmonic vibration between the engine and the turbo chargers would cause the turbos to rattle themselves apart. Often the 6000's would come through with just the turbo hold down bolts missing. Some were worse. - another problem, GE may have done this for a reason (I'm no engineer) but the crankshafts aren't hardened. If anything were to strike the journals, severe damage would result. More than once when the first power assemblies were changed on them, the mechanical forces would sometimes forget to remove the connecting rod bearing cap studs and they would strike the crank as the assembly was being removed. - a faulty design of the connecting rod has lead to many failures of the connecting rod bearing cap studs due to extensive flexing of the journal area of the connecting rod. These studs are very labor intensive to change and just trying to get them out can be extermely dangerous as they can be under alot of tension (22,000 pounds)(I have witnessed them come flying out like a bullet, and with the weight of the removal tool about 20 pounds,I think they'll take an arm off sooner or later) and if they snap off during operation severe damage can result - because of the excessive flexing of the connecting rod at the journal has lead to the failure of the aluminum bearings (which are a real pain in the nuts to align in the first place) - they have had problems with the fuel pumps and nozzles wearing out (EMD's have unit injectors - the job of compressing and injecting is done right within the injector) (always a problem associated with running higher fuel pressures) overall the 6000 engine wouldn't be half bad if it was designed right, they are just raw horsepower and they can sure PULL!
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