Series 60 DDEC VI Troubleshooting – Section 2.5 Rocker Arm Shaft Plugs Missing (New or Rebuilt Engines Only)

Section 2.5
Rocker Arm Shaft Plugs Missing (New or Rebuilt Engines Only)

If engine is not new or has not been rebuilt, refer to "2.6 Restricted Oil Cooler" .‪

To determine if a missing rocker arm shaft plugs are causing low oil pressure, perform the following steps:‪

1. Remove the rocker arm cover, (two piece, three piece); refer to appropriate service manual, engine chapter.
2. Visually inspect the rocker arm shaft for missing or leaking shaft plugs.
   1. If the shaft plugs are present and are not leaking, check the oil cooler for restriction; refer to "2.6 Restricted Oil Cooler" .
   2. If the shaft plugs are missing, refer to "2.5.2 Missing Rocker Arm Shaft Plug Repair" .
   3. If the shaft plugs are leaking, refer to "2.5.1 Leaking Rocker Arm Shaft Plug Repair" .

Section 2.5.1
Leaking Rocker Arm Shaft Plug Repair

Perform the following steps to repair leaking rocker arm shaft plugs:‪

1. Remove damaged shaft plugs; refer to appropriate service manual, engine chapter.
2. Inspect rocker arm shaft for damage. If damage is found, replace the rocker arm shaft; refer to appropriate service manual, engine chapter.
3. Install new shaft plugs; refer to appropriate service manual, engine chapter.

   Note: Shaft plug must be installed 1.0 - 1.3 mm (0.040 -0.050 in.) below surface using J–36236 .

4. Install rocker arm cover; refer to appropriate service manual, engine chapter.
5. Verify repair made to the rocker shaft plugs; refer to "2.5.2.1 Test Engine with Repaired Rocker Shaft Plugs" .

Section 2.5.2
Missing Rocker Arm Shaft Plug Repair

Perform the following steps to repair missing rocker arm shaft plugs:‪

1. Inspect rocker arm shaft for damage. If damage is found, replace the rocker arm shaft; refer to appropriate service manual, engine chapter.
2. Install new shaft plugs; refer to appropriate service manual, engine chapter.

   Note: Shaft plug must be installed 1.0 - 1.3 mm (0.040 -0.050 in.) below surface using J–36236 .

3. Install rocker arm cover; refer to appropriate service manual, engine chapter.
4. Verify repair made to the rocker shaft plugs; refer to "2.5.2.1 Test Engine with Repaired Rocker Shaft Plugs" .

Section 2.5.2.1
Test Engine with Repaired Rocker Shaft Plugs

Perform the following steps to determine if repaired rocker shaft plugs resolved low oil pressure:‪

1. Connect to DDDL 7.0.
2. Start and run engine speed at 1800 rpm.
3. Check DDDL 7.0 for oil pressure reading.
   1. If DDDL 7.0 indicates 241 kPa (35 psi) or more at 1800 rpm, shut down the engine and disconnect DDDL 7.0. No further troubleshooting is required.
   2. If DDDL 7.0 indicates less than 241 kPa (35 psi) at 1800 rpm, shut down the engine and disconnect DDDL 7.0. Check the oil cooler for restriction; refer to "2.6 Restricted Oil Cooler" .