Dps 275 service manual

Among the company's innovations in the field of shipbuilding are a tilt-turn column and Duoprop counter-rotating screws. In recent years, Volvo Penta has proposed a new propulsion system with pulling screws and a joystick to control it.

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Securely support any machine elements that must be raised for service work. On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine. On self-propelled equipment, disconnect battery ground cable - before making adjustments on electrical systems or welding on machine. Keep all parts in good condition and properly installed. Fix damage immediately.

Replace worn or broken parts. Remove any buildup of grease, oil, or debris. Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. For loosening and tightening hardware, use the correct size tools. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.

Install all guards and shields. Engines can be identified from the serial number plate A located on the right-hand side of engine. Each engine has a digit John Deere engine serial number B giving the following information:.

CDC CD The second line of information on Saran serial number plate D may also contain the coefficient of absorption value for smoke emissions or, for later engines, an internal factory identification number. Torreon Engine Plate with early numbering system. An option code label is secured to the top of the valve cover and identifies the factory installed options on each OEM engine to ensure correct parts acquisition.

Always provide option code information and engine base code when ordering repair parts. Option Code Label. Emission certified engines have a label, like the one shown, stuck on the rocker arm cover. Information on this label states the conditions this engine is emission certified. Right-hand side is the camshaft side while left-hand side is the fuel injection pump side. Cylinder number 1 is at the front of engine. Without fan. The direct fuel injection is provided by a rotary-type injection pump and 9.

Injection pump is driven by the crankshaft through the timing gear train. A cold start advance system allows easy start-up when engine is cold. The pistons are made of high-grade cast aluminum alloy with internal ribbing. The skirt is cam ground to allow for expansion during operation.

The piston crown has a cut-out re-entrant bowl swirl chamber to reduce particulate matters and smoke. The three piston rings, 2 for compression and 1 for oil control, are located above piston pin. The top compression ring is a keystone shaped ring located close to the top of piston for improved engine performance. The hardened piston pins are fully-floating and held in position by means of snap rings.

Spray jets piston cooling orifices in cylinder block spray pressurized oil on the underside of the piston to lubricate piston pins and cool pistons. The crankshaft is a one-piece, heat treated, nodular-iron. It is supported in replaceable two-piece main bearings machined to close tolerances. The rear thrust bearing has a flange on each side to support crankshaft thrust and to limit end play. Some connecting rods have a tapered pin-end while others have a straight pin-end.

The camshaft is timed to the crankshaft through the timing gear train. Camshaft rotates in a bushing for the no. The camshaft lobes determine duration and lift of each valve, and operate the fuel supply pump. The intake and exhaust valves are supported in the cylinder head.

The valve stems slide in bores in the cylinder head. The rocker arm shaft assembly is fitted on top of the cylinder head. The engine is supplied with lubricating oil by a gear pump. The lubricating oil passes through a full-flow oil filter in the main oil circuit. To ensure engine lubrication, the oil filter is provided with a by-pass valve which opens when the filter element is restricted.

On most engines, engine oil is cooled by means of an oil cooler mounted externally on the cylinder block. Engine oil passes through the oil cooler before flowing to the oil filter. A by-pass valve located between oil pump and main gallery relieves any pressure build-up in this area. The engine has a pressurized cooling system, consisting of radiator, water pump, multi-blade fan and thermostat.

Some engines are equipped with a turbocharger. Operated by exhaust gases, the turbocharger draws in filtered air to the combustion chambers. The connecting rods have a bronze bushing as bearing surface for the piston pins. The steel-backed. Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Required fuel properties In all cases, the fuel shall meet the following properties: Cetane number of 45 minimum. Consult your local fuel distributor for properties of the bio-diesel fuel available in your area. A major environmental benefit of bio-diesel fuel is its ability to biodegrade. This makes proper storage and handling of bio-diesel fuel especially important. Areas of concern include:. If oil becomes diluted with fuel, shorten oil change intervals accordingly.

Handling and Storing Diesel Fuel When using bio-diesel fuel, the fuel filter may require more frequent replacement due to premature plugging. Do not fill the fuel tank when engine is running. DO NOT smoke while you fill the fuel tank or service the fuel system. Keep all storage tanks as full as practicable to minimize condensation. Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering. Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution of the engine oil.

If a new filler cap is required, always replace it with an original vented cap. When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to stabilize the fuel and prevent water condensation.

Contact your fuel supplier for recommendations. Use oil viscosity based on the expected air temperature range during the period between oil changes. Consult your John Deere dealer for more information.

Multi-viscosity diesel engine oils are preferred. Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates. If diesel fuel with sulfur content greater than 0. DO NOT use diesel fuel with sulfur content greater than 1. Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used. Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination.

Store containers on their side to avoid water and dirt accumulation. In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

They also require periodic replenishment of additives during the drain interval. If these coolants are unavailable, use a coolant concentrate or prediluted coolant with a quality additive package that provides cylinder liner cavitation protection and protects the cooling system metals cast iron, aluminum alloys, and copper alloys such as brass from corrosion.

Coolants meeting ASTM D do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval. General Information Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. Drain Intervals for Diesel Engine Coolant Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 3 years or hours of operation.

Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant. Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants. Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required. Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible. Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application.

For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Always replace shear bolts with identical grade. Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original.

Grade 2 applies for hex cap screws not hex bolts up to 6. Grade 1 applies for hex cap screws over 6 in. Cap or plug all openings on engine. If electrical components starting motor, alternator, etc To do so may cause seizure of pump parts.

Approved lifting straps are designed only to lift the engine and small accessories, such as hydraulic pump or air compressor mounted to the engine auxiliary gear drive, or belt-driven components, such as air conditioning compressor or alternator.

Carefully lift engine and slowly lower to desired location. Safety Precautions This repair stand should be used only by qualified service technicians familiar with this equipment. To maintain shear strength specifications, alloy steel SAE Grade 8 or higher cap screws must be used to mount adapters or engine. For full thread engagement, be certain that tapped holes in adapters and engine blocks are clean and not damaged.

To avoid structural damage or personal injury, do not exceed the maximum weight capacity. When engine weight is more than kg lb. To prevent possible personal injury due to engine slippage, recheck to make sure engine is solidly mounted before releasing support from engine lifting device. Never permit any part of the body to be positioned under a load being lifted or suspended. Accidental slippage may result in personal injury. NOTE: In case of turbocharged engine with low-profile design, remove turbocharger before mounting engine onto repair stand.

Drain all engine oil and coolant. NOTE: Hydraulic lock occurs when trapped oil in the oil filter housing drains through the turbocharger, the exhaust and intake manifolds, and then into the cylinder head. After starting the engine, the trapped oil in the manifold and head is released into the cylinders filling them with oil causing hydraulic lock and severe engine damage.

The following sequence is suggested when complete disassembly for overhaul is required. Refer to the appropriate repair group when removing individual engine components.

Drain all coolant and engine oil. Check engine oil for metal contaminates see Groups 25 and Remove timing gear cover see Group Remove turbocharger if equipped and exhaust manifold see Group Remove oil pump drive gear, outlet tube and its O-ring in block and pump body see Group Remove rocker arm cover with vent tube.

On engines having an Option Code label on rocker arm cover, be careful not to damage label see Group Remove oil deflector, timing gears and camshaft. Perform wear checks see Group Remove engine front plate see Group Remove rocker arm assembly and push rods. Keep rods in sequence see Group Check for bent push rods and condition of wear pad contact surfaces on rockers.

Remove thermostat housing and by-pass tube see Group Remove oil cooler piping and water pump see Groups 25 and Remove dipstick, oil filter, and engine oil cooler. Discard standard-flow oil cooler if oil contained metal particles see Group Remove starting motor. Remove fuel filter, fuel transfer pump, and fuel lines see Group Remove injection lines, injection pump, and injection nozzles see Group Remove lube oil system by-pass valve see Group Remove flywheel and flywheel housing see Group Stamp cylinder number on rod if required.

Remove pistons and rods. Remove main bearings and crankshaft. Remove cylinder linersand mark each one with cylinder number from which removed see Group Remove piston cooling orifices see Groups 10 and Remove camshaft bushings if equipped , see Group Sealant Application Guidelines Listed below are sealants which have been tested and are used by the John Deere factory to control leakage and assure hardware retention. Use the following. Studs: Water pump-to-cylinder block Injection pump-to-front plate Exhaust manifold-to-turbocharger Oil filter nipple.

The following re-assembly sequence is suggested when engine has been completely disassembled. Be sure to check run-out specifications, clearance tolerances, torques, etc. Refer to the appropriate repair group when assembling engine components. Install all plugs and serial number plates in cylinder block that were removed to service block see Groups 10 and Install cylinder head gasket, cylinder head, push rods, and rocker arm assembly see Group Install oil pressure regulating valve, see Group Install cam follower in the same sequence as removed see Group Install cylinder liners without O-rings and measure protrusion.

Install liners with O-rings see Group Install engine oil cooler, new oil filter, and dipstick. Never clean or reuse a contaminated standard-flow oil cooler.

Install a new one see Group Install pistons and rods. Check for piston protusion see Group Install lube oil system by-pass valve. Install crankshaft pulley see Group Install alternator, fan, and fan belts see Group Install camshaft,upper and lower timing gears, and oil deflector see Group Engine break-in guidelines Engine break-in should be performed after overhaul or when the following repairs have been made:.

Cylinder head has been removed. Injection pump has been removed or critical adjustments have been made while it is on the engine. Primary objective is to check power. Main bearings, rod bearings, crankshaft, or any combination of these parts have been replaced.

Pistons, rings, or liners have been replaced. Rear crankshaft oil seal and wear sleeve have been replaced. Primary objective is to see if oil seal still leaks. Perform engine break-in Use a dynamometer to perform the following break-in procedure. Time 5 minutes.

After break-in, run the engine for 1 or 2 minutes at rpm, no load, before shutting it off. Check and reset the valve clearances. During the first hours of operation, avoid overloading, excessive idling and no-load operation. After hours, drain the crankcase oil and change the oil filter. Fill the crankcase with oil of the specified viscosity.

Change the oil and filter after the first hours of operation of a new or rebuilt engine. Valve lift—Specification Intake valve—Valve lift at 0.

Wear Tolerance Exhaust valve—Valve lift at 0. Adjust valve to zero clearance. Rotate engine and observe indicator reading as valve moves to the fully open position. Compare readings with specifications. Repeat above procedure for all valves and readjust valves to specified clearance after this operation. If valve lift is not within specification, remove and inspect camshaft.

NOTE: Before removal, mark all parts so that they can be reinstalled in their original positions. Remove exhaust manifold A. On turbocharged engine, disconnect oil inlet line B and oil return line C , then remove the exhaust manifold and the turbocharger with air inlet as an assembly.

Remove thermostat housing D , by-pass tube E and thermostat. NOTE: Removal of fuel injection nozzles is necessary to prevent them being damaged when cylinder head is removed. Mark a reference mark in-line on socket A and cylinder head surface B b. In case of cylinder head failure, record torque of each bolt before removing. These values can be asked by the factory for further investigations. To record bolt torque, proceed as follows:.

NOTE: Do not turn crankshaft after removal of cylinder head until each liner has been secured with washer and cap screw. Lift cylinder head from block. If cylinder head sticks, use a soft hammer to tap cylinder head. Do not use screw driver or prybar which can damage the sealing surface.

Otherwise tool will get dull. Release spring tension and remove valve rotator and valve spring. Mark each part so that it can be reassembled in the same position it was removed from. Check lengthwise, crosswise, and diagonally in several places. Specification Combustion face—Flatness Maxi New cylinder head—Thickness Refaced cylinder head—Minimum thickness Cylinder head combustion face— Surface finish Valve guide—Specification Cylinder head bore—Diameter Guide-to-valve stem—Clearance Wear tolerance Oversized valve stem—Specification 1st size—Diameter If valve guide-to-stem oil clearance exceeds the wear limit, 0.

Have valve guides reamed by a qualified workshop to assure the proper guide-to-stem clearance. If valve guide-to-stem oil clearance exceeds the wear limit, but is less than 0. However, installing oversize valve stems is preferred. Be sure, when valve guides are reamed that this groove is restored. Use kit exactly as directed by the manufacturer.

After knurling, ream valve guide to finished size to provide specified stem-to-guide clearance. Specification Valve seat—Width Maximum runout Check seat width and contact pattern between seat and valve with blueing. If necessary lap the valve onto its seat using a lapping tool and lapping compound.

Specification Intake Valve—Recess After lapping valve seat or remachining combustion face, install refaced or new valves in cylinder head and check valve recess A. Remove Valve Seat Inserts Valve seat inserts are made of sintered metal. Following methods, performed by experienced personnel or specialized workshop, can be used to remove inserts. Using an Arc Welder 1. Protect the valve guide by installing a cap screw or dowel in guide to protect from weld spatter.

Apply a thin bead of weld B around internal diameter of valve seat insert. Allow insert to cool and use a screwdriver C or similar tool and carefully pry insert from bore.

After removal of inserts, thoroughly clean area around valve seat bore and inspect for damage or cracks. Replace cylinder head as necessary. Machine insert according to valve seat bore specifications as shown, until a thin layer of material stays in cylinder head.

Exhaust valve seat—Specification Bore—Diameter Chamfer height Reference Depth Chamfer angle Maxi Intake valve seat—Specification Bore—Diameter Lap valve seats to maintain correct valve recess and valve to valve seat sealing. Specification Intake valve insert—Outside diameter Exhaust valve insert—Outside diameter Thoroughly clean and inspect valves to help determine if they can be reused. Replace valves that are burned, cracked, eroded, or chipped.

Specification Intake valve head—Diameter Exhaust valve head—Diameter Specification Intake Valve Stem—Diameter Exhaust Valve Stem—Diameter Check for valve face runout and bent valves. Specification Valve Face—Maximum permissible runout Specification Valve face—Angle Replace if necessary. Specification Valve Spring Compression—Free length Load with spring compressed to 46 mm 1.

Load with spring compressed to Install Valves 1. Apply engine oil to valve stems and guides. Insert valves in head in same location as found during removal. NOTE: After having installed the valves, strike end of each valve three times with a soft mallet to ensure proper positioning of the keepers. Use compressed air to remove debris or any fluids from cap screw holes. Install new cylinder head gasket dry without sealant. IMPORTANT: Without guide studs, the Viton O-ring attached to cylinder head gasket at rocker arm lube oil passage could be damaged when repositioning cylinder head on engine block to align cap screw holes.

Install two guide studs in cylinder block at locating holes B. NOTE: Always use new cap screws to install cylinder head. Dip new cap screws entirely in clean engine oil. Remove guide studs and install cap screws in all open bores. Tighten cap screws in sequence to the torque specified, beginning with No.

Cylinder head bolts—Specification 1st step—Torque Line scribe method:. JT Torque Angle Gauge. Place socket on cap screw so that first mark aligns with mark on cylinder head. Tighten in sequence all cap screws until second mark on socket aligns with mark on cylinder head. NOTE: The torque turn method eliminates the need to retorque the cylinder head bolts after the first hours of engine operation. However, valve clearance adjustment is still required.

Disassembling and Checking Rocker Arm Shaft 1. Remove plugs C and bowed washers F from rocker arm shaft. Slide springs, rocker arms and supports off rocker arm shaft, identifying their sequence for reassembly in the same order.

Clean all parts with solvent and dry with compressed air. Check all parts for good condition. Rocker arm—Specification Shaft—Diameter Spring—Load at 46 mm 1.

NOTE: If the rocker arm has been damaged by a valve failure, replace it together with the corresponding push rod, valve rotator and keepers. In this case, when re-assembling this engine, use the R flanged head cap screws without washer. NOTE: Effective with following engine serial numbers, shaft A and cap screw D with washer E have been replaced by a new shaft and flanged head cap screws.

Lubricate shaft, bores of rocker arms and supports. Slide springs, rocker arms and supports onto shaft. Assemble in the same order in which they were removed during disassembly. Refer to appropriate Parts Catalog for more details.

Some engines built after above engine serial numbers may have been assembled with the. Install bowed washers F and new plugs C on shaft. Lubricate the rocker arms with engine oil. Tighten attaching cap screws to specifications. Specification Rocker arm support cap screw— Torque Specification Intake Valve—Clearance Exhaust Valve—Clearance Adjust valve clearance on No. Specification Valve clearance—Firing order Specification Rocker arm cover cap screw— Torque Install the cap screws by hand and tighten to specifications, starting from center and moving towards both front and rear ends of the cover.

Clean cover sealing ring groove with acetone and dry with compressed air. Install new sealing ring with grease in cover groove. Cut the sealing ring slightly longer than necessary. Put the sealing ring ends edge to edge then press the sealing ring all along the groove to ensure proper installation. Re-install parts previously removed. Check crankcase vent tube hose A for proper condition. Services Provided by Other Agencies. Services Provided by Other Agencies Spanish.

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