Service intervals are based upon average operating conditions. Where dusty, frequent start and stop or heavily laden operations are encountered, more frequent servicing will be required.
Check oil level daily.
Check the oil level by removing the oil level gage from the oil fill tube and observe. Ensure the oil level is at the FULL mark on the oil level gage. See Figure 31797 . If the oil level is below FULL, fill with the proper grade of oil for the temperature. Do not overfill past the FULL mark.
Checking Oil Level
Check coolant level daily.
Check water separator, (fuel system) daily. Drain water from the fuel system as follows:
Inspect Air-to-Air Intercooler daily.
Chassis Mounted Air-to-Air Intercooler
Inspect for external leakage daily. Visually inspect for leakage as follows:
Inspect Air Cleaner Restriction Indicator daily. Refer to section for inspection procedure.
Service the air cleaner as follows:
Inspect belt daily. Check belt for worn, grease coated, oil soaked and missing material. Replace as necessary. Install new belt as follows:
Note: When installing belt, place it around the inside edge of the belt tensioner.
Change engine oil and oil filter as follows. If fuel contains more than 0.05% sulfur, reduce the oil change intervals listed in Table .
Sulfur Content, Percent
Oil Change Interval
0.5 to 1.0
Do not overtighten filter. A damaged filter may fracture or leak.
Check coolant SCA concentration.
Every six months, check the coolant concentration level in the coolant. Refer to section for further information.
Inspect air intake piping every six months. See Figure 31581 .
Air Intake Piping
Measure air intake restriction every 12 months or 900 hours.
Note: The air cleaner is to be serviced only when the restriction reaches the maximum allowable limit. The restriction can be measured by the service indicator.
Note: Often a low power and poor fuel economy complaint is simply due to a dirty air cleaner. As the air cleaner accumulates dirt, restrictions to airflow increases. If the service indicator is locked at maximum restriction, replace the air cleaner elements.
The dual element air cleaner provides a large primary (outer) filter element and optional small secondary (inner) filter element. The secondary element should be used in dusty environments such as dump and mixer applications. See Figure 31804 .
1. Secondary (Inner) Element
3. Inner Element Retaining Nut with Restriction Indicator
2. Air Cleaner Housing
Top View of Dual Element Air Cleaner with Retaining Nut Indicator
The current dual element air cleaner restriction indicator assembly is located between the primary and the secondary element in the bottom of the air cleaner housing. This arrangement allows only the primary element to be sensed by the restriction indicator or dash mounted vacuum gage. The inner element is not recorded on the restriction indicator or dash mounted vacuum gage.
A separate inner element indicator senses restriction of that element. Dependent upon the manufacturer, either a rectangular wing nut with a built-in indicator is used or an element with an indicator located on the inner element end cap. See Figure 31805 . When all green disappears on the wing nut indicator, replace the inner element. When the green dot disappears from the indicator built into the inner element end cap, replace the inner element.
1. Secondary (Inner) Element
3. End Cap with Restriction Indicator
2. Air Cleaner Housing
Top View of Dual Element Air Cleaner with Indicator in End Cap
Change fuel filter and strainer assembly every 12 months. Fuel with more than average impurities may require changing the filter and strainer assembly at shorter intervals. See Figure 31800 . Use the following procedure:
1. Fuel Filter
2. Fuel Filter Header
5. Strainer Cover
Removing Strainer Assembly
Note: Install strainer with open end toward filter header.
Note: Do not add fuel to new fuel filter.
Change coolant filter every 12 months using the following procedure.
Note: Coolant filter header is equipped with two check valves to stop flow of coolant when filter is removed.
Service cooling system every 100,000 miles (161,000 km) for the 7.6L engine, and every 180,000 miles (290,000 km) for the 8.7L engine.
To avoid injury from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Remove the cap slowly to relieve pressure. Wear adequate protective clothing (face shield or safety goggles, rubber gloves, apron, and boots).
Drain and fill the cooling system as follows:
Clean the cooling system as follows.
If the coolant is extremely low and the engine is very hot, let the engine cool for approximately 15 minutes before adding coolant. Then, with the engine running, add coolant slowly. Adding cold water to a hot engine may crack the cylinder head or crankcase. Never use water alone!
The cooling system should be drained and thoroughly flushed. Refer to section 13.4.14.
Unless the cooling system is treated with a corrosion preventative, rust and scale will eventually clog up passages in the radiator and water jackets. This condition is aggravated in some localities by formation of insoluble salts from the water used.
DDC cleaning solutions are available which have proven very successful in removing accumulation or rust, scale, sludge and grease. They should be used according to the recommendation on the container.
Note: Do not use chemical mixtures to stop radiator leaks except in an emergency. Never use such solutions instead of needed radiator repair.
Check the radiator fins periodically to make sure they are free of bugs, leaves and other debris, and that they are not bent or damaged. Clogged or damaged fins prohibit the flow of outside air to the radiator and hamper efficient cooling system operation.
Only coolants with an ethylene glycol or a propylene glycol base are recommended for use in the Series 40E cooling systems. Other base coolants may damage rubber hoses, especially those made of silicone rubber. Type of rubber can usually be determined by color. Silicone hoses are made in COLOR while other rubber hoses are BLACK .
Coolant made with methoxy propanol is not recommended for use with Detroit Diesel Corporation engines. These types of coolant can damage engine internal seals and coolant hoses, and create a potential fire hazard due to lower flash points than ethylene glycol.
Note: Avoid mixing propylene glycol antifreeze and ethylene glycol antifreeze in any diesel engine cooling system. This mixing of antifreeze solutions does not allow an accurate coolant solution reading for freeze protection.
The cooling system will most likely be filled with ethylene glycol coolant. It is recommended that an ethylene glycol coolant be added to the system when required.
Your new engine is equipped at the factory with a high temperature thermostat.
Note: Ethylene glycol antifreeze must be used with high temperature thermostats.
Inspect vibration damper every 24 months.
Pressurize induction system every 24 months.
Adjust valve lash every 120,000 miles (193,100 km).
Measure crankcase pressure every 200,000 miles (290,000 km).
Inspect turbocharger every 180,000 miles (290,000 km).
Inspect the electrical system annually.