Diagnosing Starting Issues in Detroit Diesel Series 60 Engines

[MikePhua]

Introduction
The Detroit Diesel Series 60 engine, introduced in 1987, revolutionized the heavy-duty diesel engine market with its fully electronic control system, the Detroit Diesel Electronic Control (DDEC). This innovation allowed for precise monitoring and management of engine parameters, leading to improved performance and fuel efficiency. However, like any complex system, the Series 60 is not immune to starting issues. Understanding the common causes and diagnostic steps can help in efficiently addressing these problems.
Common Causes of Starting Problems

1. Fuel System Issues
   • Clogged Fuel Filters: Over time, fuel filters can become clogged with contaminants, restricting fuel flow to the engine. This can lead to hard starting or no-start conditions.
     
   • Air in Fuel Lines: Air entering the fuel lines can cause the engine to lose its prime, making it difficult to start. This is often due to loose connections or cracks in the fuel lines.
     
   • Faulty Fuel Injectors: Worn or malfunctioning injectors can lead to improper fuel atomization, causing poor combustion and starting difficulties.
     
2. Electrical System Problems
   • Weak or Dead Batteries: Insufficient battery voltage can prevent the starter motor from turning over the engine properly. It's essential to check the battery charge and condition regularly.
     
   • Faulty Sensors: The Series 60 engine relies on various sensors, such as the Crankshaft Position Sensor (CKP) and the Timing Reference Sensor (TRS), to determine engine timing. A failure in these sensors can lead to starting issues.
     
3. Glow Plug Malfunctions
   Glow plugs are crucial for cold starts, especially in low-temperature conditions. If a glow plug fails, it can prevent the engine from starting in cold weather.
   
4. Loss of Fuel Prime
   The engine requires a certain level of fuel pressure to start. If the fuel system loses its prime, the engine may crank without starting. This can be due to a faulty check valve or air entering the fuel lines.
   

Diagnostic Steps

1. Check Battery Voltage
   Ensure that the batteries are fully charged and in good condition. Weak batteries can cause insufficient cranking speed, leading to starting issues.
   
2. Inspect Fuel System
   • Replace Fuel Filters: Clogged filters should be replaced to ensure proper fuel flow.
     
   • Check for Air Leaks: Inspect fuel lines for cracks or loose connections that could allow air to enter the system.
     
   • Verify Fuel Quality: Ensure that the fuel is clean and free from contaminants.
     
3. Test Sensors
   Use a diagnostic tool to check the functionality of the CKP and TRS sensors. If either sensor is faulty, it should be replaced.
   
4. Inspect Glow Plugs
   Test each glow plug to ensure it is functioning correctly. Replace any faulty glow plugs to improve cold-start performance.
   
5. Prime the Fuel System
   If the engine has lost its prime, use the manual priming pump to restore fuel pressure. Ensure that all air is purged from the fuel lines.
   

Preventive Maintenance Tips

• Regularly Replace Fuel Filters: Change fuel filters at the manufacturer's recommended intervals to prevent clogging and ensure proper fuel flow.
  
• Monitor Battery Health: Regularly check battery voltage and condition to ensure reliable starting.
  
• Inspect Fuel Lines for Leaks: Regularly check fuel lines for cracks or loose connections that could allow air to enter the system.
  
• Test Sensors Periodically: Use diagnostic tools to periodically check the functionality of critical sensors.
  
• Maintain Glow Plugs: Regularly test and replace glow plugs to ensure reliable cold-start performance.
  

Conclusion
The Detroit Diesel Series 60 engine is a robust and reliable powerplant widely used in heavy-duty applications. However, starting issues can arise due to various factors, including fuel system problems, electrical system malfunctions, and glow plug failures. By understanding the common causes and following systematic diagnostic steps, operators can efficiently address these issues and maintain optimal engine performance. Regular preventive maintenance is key to ensuring the longevity and reliability of the Series 60 engine.