Section 14

Preventive Maintenance

Section 14.1
Maintenance Overview

The lubrication and preventive maintenance schedule is intended as a guide for establishing a preventive
maintenance schedule. The suggestions and recommendations for preventive maintenance should be
followed as closely as possible to obtain long life and best performance from the Series 60 engine. The
intervals indicated are time or miles of actual operation.

The time or mileage increments shown apply only to the maintenance function described. These functions
should be coordinated with other regularly scheduled maintenance such as chassis lubrication.

The daily instructions pertain to routine or daily starting of an engine and not to a new engine or one that
has not been operated for a considerable period of time. For new or stored engines, carry out the
instructions given under "Preparation for a First Time Start." Refer to "12.1 Preparation for a First Time
Start" .

The daily maintenance of Series 60 engines is the same for all applications. Refer to "14.2 Daily
Maintenance - All Applications" . Periodic maintenance of Series 60 engines is dependent on the
application. For engines installed in vehicles, refer to "14.3 Maintenance of Vehicle Engines" .

EPA07 Series 60 Workshop Manual (DDC-SVC-MAN-0005)

Section 14.2
Daily Maintenance - All Applications

The following items need to be inspected, serviced, corrected or replaced on a daily basis, as necessary:

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Fuel tank, refer to "14.4.2 Fuel Tanks"
 Fuel lines and flexible hoses, refer to "14.4.3 Fuel Lines and Flexible Hoses"
 Cooling system, refer to "14.4.4 Cooling System"
 Turbocharger, refer to "14.4.7 Turbocharger"

EPA07 Series 60 Workshop Manual (DDC-SVC-MAN-0005)

Copyright © 2012 by Detroit Diesel Corporation. All rights reserved.

Generated on 02-14-2012
Section 14.3
Maintenance of Vehicle Engines

Vehicle engine components must be maintained at various intervals.

Section 14.3.1
12,000 km (7,500 Miles) Interval Maintenance

Every 12,000 km (7,500 miles), the following components must be inspected, serviced, corrected or
replaced as necessary.

 Battery, refer to "14.4.8 Battery"

 Drive belts, refer to "14.4.9 Drive Belts"
 Air compressor, refer to "14.4.10 Air Compressor"

Section 14.3.2
24,000 km (15,000 Miles) or 6 Month Interval Maintenance

Every 24,000 km (15,000 miles) or 6 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Air cleaner, refer to "14.4.11 Air Cleaner"

Likewise, the following components must be replaced every 24,000 km (15,000 miles) or 6 months.

 Lubricating oil, (Severe)refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, (Severe)refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.3
32,000 km (20,000 miles)

Every 32,000 km (20,000 miles) or 6 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Lubricating oil, (Short Haul)refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, (Short Haul)refer to "14.4.12 Lubricating Oil Filter"

Section 14.3.4
48,000 km (30,000 Miles) or 12 month Interval Maintenance

Every 48,000 km (30,000 miles) or 12 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Fuel tank, refer to "14.4.2 Fuel Tanks"

 Drive belts, refer to "14.4.9 Drive Belts"
 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"
 Engine (steam clean), refer to "14.4.18 Engine (Steam Clean)"
 Radiator and air-to-air charge cooler, refer to "14.4.19 Radiator"
 Battery charging alternator, refer to "14.4.21 Battery Charging Alternator"
Likewise, the following components must be replaced every 48,000 km (30,000 miles) or 12 months.

 Lubricating oil, (Long Haul) refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, (Long Haul) refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.5
72,000 km (45,000 Miles) or 18 Month Interval Maintenance

Every 72,000 km (45,000 miles) or 18 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Drive belts, refer to "14.4.9 Drive Belts"

 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"

Likewise, the following components must be replaced every 72,000 km (45,000 miles) or 18 months.

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.6
97,000 km (60,000 Miles) or 24 Month Interval Maintenance

Every 97,000 km (60,000 miles) or 24 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Fuel tank, refer to "14.4.2 Fuel Tanks"

 Cooling system, refer to "14.4.4 Cooling System"
 Drive belts, refer to "14.4.9 Drive Belts"
 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"
 Engine (steam clean), refer to "14.4.18 Engine (Steam Clean)"
 Radiator and air-to-air charge cooler, refer to "14.4.19 Radiator"
 Oil pressure, refer to "14.4.20 Oil Pressure"
 Engine tune-up, refer to "14.4.28 Engine Tune-up" .
 Battery charging alternator, refer to "14.4.21 Battery Charging Alternator"
 Engine and transmission mounts, refer to "14.4.22 Engine and Transmission Mounts"
 Crankcase pressure, refer to "14.4.23 Crankcase Pressure"
 Thermostats and seals, refer to "14.4.26 Thermostats and Seals"
 Crankcase breather, refer to "14.4.27 Crankcase Breather"

Likewise, the following components must be replaced every 97,000 km (60,000 miles) or 24 months.

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"
Section 14.3.7
121,000 km (75,000 Miles) or 30 Month Interval Maintenance

Every 121,000 km (75,000 miles) or 30 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Drive belts, refer to "14.4.9 Drive Belts"

 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"

Likewise, the following components must be replaced every 121,000 km (75,000 miles) or 30 months.

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.8
145,000 km (90,000 Miles) or 36 Month Interval Maintenance

Every 145,000 km (90,000 miles) or 36 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Fuel tank, refer to "14.4.2 Fuel Tanks"

 Drive belts, refer to "14.4.9 Drive Belts"
 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"
 Engine (steam clean), refer to "14.4.18 Engine (Steam Clean)"
 Radiator and air-to-air charge cooler, refer to "14.4.19 Radiator"
 Battery charging alternator, refer to "14.4.21 Battery Charging Alternator"
 Alternator and attaching hardware, refer to "14.4.31 Alternator and Attaching Hardware"
 Air conditioning and attaching hardware, refer to "14.4.32 Air Conditioning and Attaching
Hardware"
 Air compressor and attaching hardware, refer to "14.4.33 Air Compressor and Attaching
Hardware"

Likewise, the following components must be replaced every 145,000 km (90,000 miles) or 36 months.

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.9
169,000 km (105,000 Miles) or 42 Month Interval Maintenance

Every 169,000 km (105,000 miles) or 42 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Drive belts, refer to "14.4.9 Drive Belts"

 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"
Likewise, the following components must be replaced every 169,000 km (105,000 miles) or 42 months.

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.10
193,000 km (120,000 Miles) or 48 Month Interval Maintenance

Every 193,000 km (120,000 miles) or 48 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Fuel tank, refer to "14.4.2 Fuel Tanks"

 Cooling system, refer to "14.4.4 Cooling System"
 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"
 Engine (steam clean), refer to "14.4.18 Engine (Steam Clean)"
 Radiator and air-to-air charge cooler, refer to "14.4.19 Radiator"
 Oil pressure, refer to "14.4.20 Oil Pressure"
 Battery charging alternator, refer to "14.4.21 Battery Charging Alternator"
 Engine and transmission mounts, refer to "14.4.22 Engine and Transmission Mounts"
 Crankcase pressure, refer to "14.4.23 Crankcase Pressure"
 Fan Hub, refer to "14.4.25 Fan Hub"
 Thermostats and seals, refer to "14.4.26 Thermostats and Seals"
 Crankcase breather, refer to "14.4.27 Crankcase Breather"
 Engine Tune-up, refer to "14.4.28 Engine Tune-up"

Likewise, the following components must be replaced every 193,000 km 9120,000 miles) or 48 months.

 Drive belts, refer to "14.4.9 Drive Belts"

 Lubricating oil, refer to "14.4.1 Lubricating Oil"
 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.11
217,000 km (135,000 Miles) or 54 Month Interval Maintenance

Every 217,000 km (135,000 miles) or 54 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Drive belts, refer to "14.4.9 Drive Belts"

 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"

Likewise, the following components must be replaced every 217,000 km (135,000 miles) or 54 months.

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"
Section 14.3.12
241,000 km (150,000 Miles) or 60 Month Interval Maintenance

Every 241,000 km (150,000 miles) or 60 months, the following components must be inspected, serviced,
corrected or replaced as necessary.

 Fuel tank, refer to "14.4.2 Fuel Tanks"

 Drive belts, refer to "14.4.9 Drive Belts"
 Air compressor, refer to "14.4.10 Air Compressor"
 Air system, refer to "14.4.16 Air System"
 Exhaust system, refer to "14.4.17 Exhaust System"
 Engine (steam clean), refer to "14.4.18 Engine (Steam Clean)"
 Radiator and air-to-air charge cooler, refer to "14.4.19 Radiator"
 Battery charging alternator, refer to "14.4.21 Battery Charging Alternator"

Likewise, the following components must be replaced every 241,000 km (150,000 miles) or 60 months.

 Lubricating oil, refer to "14.4.1 Lubricating Oil"

 Lubricating oil filter, refer to "14.4.12 Lubricating Oil Filter"
 Fuel filter, refer to "14.4.13 Fuel Filters (Diesel)"
 Coolant filter and inhibitor, refer to "14.4.14 Coolant Filter and Water Pump"

Section 14.3.13
321,000 km (200,00 Miles) or 4000 Hours Interval Maintenance

Every 321,000 km (200,000 miles) or 4000 hours, the following component must be replaced:

 Rocker cover-mounted breather assembly and seal for closed crankcase breather system, refer to
"14.4.27 Crankcase Breather" .

Section 14.3.14
1,609,000 km (1,000,000 Miles) Interval Maintenance

Every 1,609,000 km (1,000,000 miles) the following component must be replaced:

 Bull Gear,refer to "14.4.29 Bull Gear" .

EPA07 Series 60 Workshop Manual (DDC-SVC-MAN-0005)

Copyright © 2012 by Detroit Diesel Corporation. All rights reserved.

Generated on 02-14-2012
Section 14.5
Cleaning Contaminated Lubrication Oil System

If coolant should leak into the lubrication system, the lube system must be thoroughly flushed to avoid or
limit damage using the flushing procedures outlined below.

Section 14.5.1
Before Flushing Lubrication System

The following steps must be followed before flushing the contaminated lubrication system:

1. Determine the cause of the internal coolant leak and correct the problem.
2. Thoroughly drain the lubricating oil. Take and label a representative 6-8 ounce sample for
chemical analysis.
3. Examine the drained oil:
1. Refer to "14.5.2 Flushing a Non-Gelled Oil System" if the oil is still reasonably fluid and
is typical of the used oil at regular drain intervals.
2. Refer to "14.5.3 Flushing an Oil System that Exhibits Gelling" if the oil shows a gelling
texture.
4. Inspect main bearing shells:
1. If damaged, the engine must be disassembled and checked for any additional damage.
2. If not damaged, proceed as follows:
3. Refer to "14.5.2 Flushing a Non-Gelled Oil System" if the oil on the bearing shell(s) is
viscous with normal flowing texture
4. Refer to "14.5.3 Flushing an Oil System that Exhibits Gelling" if the oil on the bearing
shell(s) has gelled up, requiring scraping to remove.

Section 14.5.2
Flushing a Non-Gelled Oil System

Use this procedure if the contaminated lubricating oil is still freely flowing without gelling. This requires
the lubricating oil recommended for normal operation.

FIRE (f9)
To avoid injury from fire caused by heated diesel-fuel vapors:

 Keep those people who are not directly involved in servicing away from the engine.
 Stop the engine immediately if a fuel leak is detected.
 Do not smoke or allow open flames when working on an operating engine.
 Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).

 To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated
during operation.
1. Remove and discard the oil filter and replace with new filters.
2. Pressure fill the lubricating system to 172 kPa (25 psi) with the lubricating oil recommended for
normal operation, making sure the crankcase is filled to the proper operating level. Refer to "5.2
Lubricating Oil (Diesel)" of the engine service manual.
 PERSONAL INJURY (eng16)
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.

o Always start and operate an engine in a well ventilated area.

o If operating an engine in an enclosed area, vent the exhaust to the outside.
o Do not modify or tamper with the exhaust system or emission control system.
3. Start and run the engine at fast idle (1000 to 1200 rpm) for 30 minutes to one hour. Check engine
running conditions frequently, especially the oil pressure, and stop immediately if a reading is out
of range.
4. Stop the engine and immediately drain the crankcase. Allow enough time to drain all the fluid.
Take and label a second oil sample.
5. Repeat steps 1 through step 5 .
6. Remove and discard all oil filters and replace with new filters.
7. Replace oil drain plugs and pressure fill the engine to the proper level with the lubricating oil
recommended for normal operation.
8. Have oil samples analyzed for coolant contamination and condition of the engine.

Section 14.5.3
Flushing an Oil System that Exhibits Gelling

Use this procedure if the contaminated oil exhibits gelling. This requires the lubricating oil recommended
for normal operation and the addition of a solvent.

FIRE (f9)
To avoid injury from fire caused by heated diesel-fuel vapors:

 Keep those people who are not directly involved in servicing away from the engine.
 Stop the engine immediately if a fuel leak is detected.
 Do not smoke or allow open flames when working on an operating engine.
 Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).

 To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated
during operation.
1. Remove and discard all oil filters and replace with new filters.

PERSONAL INJURY (cit15)

To avoid injury from improper use of chemicals, follow the chemical manufacturer's usage,
handling, and disposal instructions. Observe all manufacturer's cautions.
2. Mix two parts of the lubricating oil recommended for normal operation with one part of butyl
cellosolve. Refer to "5.2 Lubricating Oil (Diesel)" of the service manual for recommended oil.
Pressure fill the engine with this mixture to 172 kPa (25 psi) until the crankcase is filled to the
proper operating level.
 3. Refer to "14.5.2 Flushing a Non-Gelled Oil System" for exhaust caution before proceeding. Start
and run the engine at fast idle (1000 to 1200 rpm) for 30 minutes to one hour. Check engine
running conditions frequently, especially oil pressure, and stop immediately if a reading is out of
range.
4. Stop the engine and immediately drain the crankcase. Allow enough time to drain all the fluid.
Take and label a second oil sample.
5. Remove and discard all oil filters and replace with new filters.
6. Using a fresh charge of the lubricating oil recommended for normal operation, pressure fill the
engine via the oil gallery to 172 kPa (25 psi) until the crankcase is filled to the proper operating
level.
7. Refer to "14.5.2 Flushing a Non-Gelled Oil System" for the exhaust caution before proceeding.
Start and run the engine at fast idle (1000 to 1200 rpm) for 30 minutes to one hour. Check engine
running conditions frequently, especially oil pressure, and stop immediately if a reading is out of
range.
8. Stop the engine and immediately drain the crankcase. Allow enough time to drain all the fluid.
Take and label a third oil sample.
9. Remove and discard all oil filters and replace with new filters.
10. Replace oil drain plugs and pressure fill the engine to the proper level with the lubricating oil
recommended for normal operation.
11. Have oil samples analyzed for coolant contamination and condition of the engine.

This procedure should flush all coolant contamination from the lubrication system. However, a thin
coating from the coolant may still be evident on certain moving engine parts. This coating should
disappear within one or two oil changes due to the detergent and dispersant additives in the engine oil.

Note: The next oil change should be at one-half the normal oil change interval. Make sure that new filters
are installed and that an oil sample is analyzed for coolant contamination and condition of the engine.

EPA07 Series 60 Workshop Manual (DDC-SVC-MAN-0005)

Copyright © 2012 by Detroit Diesel Corporation. All rights reserved.

Generated on 02-14-2012