Inspection, repair and dynamometer test of Detroit 60 series engine

The initial enquiry from our client was to evaluate the condition of a Detroit 60 series engine installed in a badly damaged liquid nitrogen converter unit. The engine was inspected, repaired and a Dynamometer test was carried out.

On arrival at Prior Diesel Ltd our specialist team of well service equipment technician’s removed the Detroit 60 series from the damaged unit and delivered it to the service department engine build team for evaluation

Firstly the engine was cleaned and inspected externally, any damaged components identified. Next the engine rocker cover was removed to allow for a detailed inspection of the top end internal components, any issues found were fully documented.

With the top end inspection of the Detroit 60 series complete, the sump was removed to allow access to the engine bottom end internal components. The big ends were disconnected and the condition of the bearing shells and crankpins assessed. The main bearing caps were removed one at a time and the condition of the bearing shells and crankshaft journals assessed with the two thrust bearings inspected at the same time. The big ends and bearing shells were then refitted and tightened using a calibrated torque wrench in accordance with the Detroit 60 series technical manual. All critical component final torques are recorded and witness verified on a component specific document which is signed and dated by the engine build technician and witness as part of our quality assurance programme. Only calibrated torque wrenches are used during the engine build process. With the engine inspection complete a detailed full report of the condition of the Detroit 60 series was compiled and submitted to the client for consideration.

The client authorised all repairs as detailed in the submitted report and the required spare components were ordered via Prior Diesel parts department.

With all new parts fitted the engine was then installed into the Prior Diesel purpose built engine test cell which features a Froude 2000hp dynamometer test and DaTAQ Prolog data acquisition system.

Prior to starting the Detroit 60 series being a fully electronically controlled engine was connected to the DDEC control system and diagnostic computer, it was during this process that a fault code was flagged up by the engine diagnostic system which was traced to a fault with engine ECU, This was replaced with a test ECU with the correct calibration loaded.

With the test ECU installed the Detroit 60 series was cranked over with the ignition off to allow the engine oil pressure to rise and prime the lubrication system. After the engine oil level had been rechecked the engine was started for the first time. With all pressures stable and within the manufacturers specification the engine speed was raised to 1200rpm and a load of 100hp applied, this condition was maintained until the engine was at operating temperature and the thermostats had opened fully.

With the engine pressures and temperature stable the engine was run at its rated speed of 2100rpm and the load gradually increased until the full 600hp was achieved. This engine condition was maintained for a period of one hour during which the engine was constantly monitored, with critical temperatures and pressures recorded by the DaTAQ Prolog data acquisition system every 30 seconds, additionally the DDEC diagnostic computer was set to record all engine ECU data.

On completion of the test the engine was fully inspected and a full report was compiled for submission to the client for final approval.