David Brown AD4-25 Diesel Engine Full Service Repair Manual

THE DAVID BROWN DIESEL ENGINE Service , Maintenance and Repair MANUAL AD4/ 25 and CAD4 / 30 Seri es DAVID BROWN ~ "" - " -~ K I~S LIMITED SUCCE ::._ -:., .--<::; TO DAVID BROWN TRACTORS (Engineering) LIMITED MELTBAM . BUDDERSFIELD . ENGLAND flllT 1'1>". : nu U '>5 11'1

~.\(UI 2 Preface This book has been prep:tred to enable Di st ributors and dealers to carry out efficien tl y repllirs and main· lenance of AD4/ 25 and CA D-If 30 Series Diesel Engines. The informati on contained in this book is not in tended to include repairs to damaged componenls or ilem~ of proprietary manuructurc. The fuel injcc ti un equipment. which b of proprietary manufacture. has been dealt with in deta il mainly for the purpose of assisting Di st ributors lind Dc.tlers who lire remotely si lu!lIed where it is not possible to take ad va ntage of the Manufacturers' service faci lities immediately. Many Di stributors and Dealers possess equipment and hwve available specially trained engineers enabling the complete servicing of the injec ti on equipment to be c:lrried OU t. Where this is not aV:lilable it b eSSt!n ti ,, 1 to take full adv,tntagc of t he Manufacturers' depots and agents. Ea rl ier DAV ID IlROW I diesel engines prior to the introduction of the flange mounted type fuel injector pump are fu ll y described in the previous Diesel Engine Manual , puhlication No. 222. .., •

Section Index Section 1. Starting. Operating and Maintenance Section 2. The Fuel Supply and Injection Equipment Section 3. Dismantling and Assembly of the Engine Section 4. The Lubrication System Section S. The Cooling System Section 6. Electrical Equipment Section 7. Specification Section 8. Fits and Tolerances

The DAVID BROWN 25D and 30D series II tractors are iden tical in co nstruction. the larger engine unit fi lled in the 30D loe dc .. tractors is simi l ar to the 25 D tractor e'(cept in the cylinder bore and ruel injection pump selling and the larger machine is usu;.lI y equipped wi th larger size tyres to ullli£e Ihe ext ra drawbar effort.

Starting, Operating and lltlaintenctnce contents Engine Controls and Instruments To Start the Engine When Cold ( Normal ) To Start the Engine When Cold (Sub- Zero ) To Stop the Engine To Re-s tart the Engine When Warm Recommended Lubricants Lubrication Chart lSO and 300 Tractors Detergent Lubrication Oils Maintenance and Lubrication Periods Recommended Fuels, U.K. and Overseas Fuel Oil - Special Precautions Fuel Oil Storage section 1 MOl! 5 1

index Engine Controls and Instruments ". Starting the Engine When Cold ( Normal ) Starting th e Engine When Cold ( Sub-Zero ) To Stop the Engine To Re-sta rt the Engine When Warm Recommended Fuels ( United Kingdom and Overseas ) Recommended lubricants Detergent Lubricating Oils Maintenance and Lubrication Periods lubrication Chart Special Precautions when Handling Diesel Fuel Oil ... Storage of Diesel Fuel ... • .. ~c" 6 {.luge iVun l,ber 8 8 9 9 9 9 10 10 10 11 12 13

Sta rtin o ' b' OI:Jeratin o ' anci Maintenanc e . 5 section one DIESEL ENGINES AD4 ;25 and CAD430 " • F,C . 1 AD" 25 AND CA0<4 10 OIESEl ENGINE A. Oecompreuor L~~er G. fuel F iller Vent Plug M f uel Pump Vent Plu,l (2) N. fuel lift Pump B. bcess fuel Rene' Valye C. '"I_ctor Fi. ln, Studs H. Wiler Pump Spindle Lubrl. cator D. BrlUther Mountln, (Re- mov" to Uft En,ine) 1. N S (Front) fuel Filter (1) P PrImIng Pump E. ThrouleControl Venturi K. ExtUI fuel Bunon (SUI'l- Inc only) Q. fuel Cut-offCentnllever R. Ene1 n!! Onin T Ip F. Oil Filter l. In termediate Shft H01.l1in& -00 not remove S. 0,1 filter Orlln Plu, rhc Da vid Brown diesel e ngine uni tl> ,Lre oforthollox. design of th e dirCCI injection. toroidal Pi ston com· buslian chamber type. The AD4/ 25 and CAD4/30 3fC four ~'ylinder engines co ld slarting , fiUed with fin excess fuel device and full decompression of all cyli nders. Provision is made for filling an ether starling carbureltor when operating under sub-zero temperatures. Detergent lubricating oils :lre used. these preve nt ;l ny tendency for the engin e 10 ,. gum up" and withstand the heavy operating pressures. I mporlanl rhe prc~n t pruJuclion A04/ 25 and CA 04/ JO series diesel engint:s incorpo rate a Hange mounted type fuel injector pump :lnd modified pump driving gears. The crankshaft and bearings are re-designed and the nywheel mounting changed. Th is manual is excl usive to the flange mounted pump type diesel engines and references for prior production engines shou ld be made III the previous ~D I ES EL Engine Manual, Publication Number 222. I

AD4/lS Series Engines Bore 3! in. (88 ·9 mm.) Stroke 4 in. (lOI'6 mm.) Capacity 154 cu. in. (2.523 c.cs.) a.H.p. 31·3 at 1.800 r.p.m. B. H.P. 28·2 at 1.600 r.p.m. Compression Ratio 1 5·9: I. CAD4/ 30 Series Engines Bo re 3j in. (92· 1 mm.) Stroke 4 in. (101 ·6 mm.l Capacity 165 cu. in. l2,706 c.cs.) B.H.P. 34·5 at I.KOO r.p.m. B.H.P. 31·5 al 1.600 r.p.m. Compression Ralio 15·9 : I. The engines are fitted with repl aceab le wet type cylin der sleeves, phosphor-bronze gudgeon pin bearings, lead·bronze connecting rod bearings lind com- posite type main bearings. The cr~lnkshafi journal bearings arc renewable thin shell type. The bearing caps are dowelled to the engine block. The ca msha fl bearings are direct in the cylinder block. Fie . 2. CONTROLS ANO INSTRUMENTS A. L1chtlnc Switch O. Tempe r-nure Gauge 8. Ammeter E. Fuel CUt-of( Control C. 011 Pressure Gauge F. Starter Push Button Engine Controls and Instruments Governor Contr ol Leve r A hand control lever is linked 10 a thrOllle valve which in turn regulates the air pressure lIctuating the pnl!umatic governor. The pneumatic govcrnor regulates the amount of fuel supp lied to the engine i_nct so eon lrols the engine speed. When the lever is in the lowest position the engine is controlled at idling speed (700 r.p.m.) al the intermediate stop position ( 1,600 r.p.m.) :lIld when raised the maximum governed speed ( 1, 800 r.p.m.) is obt:lined. Decompressor Leve r (/\, Fig. J) This lever h<l s two positions onl y; when raised to the vertical position all cylinders arc decompressed. The running position is horizontal. Excess Fu el Bulton (Il, Fig. 3) When depressed excess fuel is permitted for cold starting. Immediately the engine fires the bulton is re·sct. Fucl C ut -O ff Contrul (E. Fig. 2) This stops the fuel sup ply when the control is r AGE 8 extended by placing the rut!! pump tllements III the •• no delivery position." O il Pressure Gauge A dial type gauge mounted on the dash pando Normal working oil prc.'isure .w Ib./sq. in. Do not operate the engine if the oil pressure is below 15 Ibs ./sq. in. Tc mpc nuur e Gau ge (D. Fi g. 2) Calibr:lIed in degrees F. Normal opcmting tem- rcnllUTe 180 ' F. Starting Instructions Do not ~Ittem pt to start Ihe engine unles'i thcre I:' an ample supply of fuel in the fuel tank. Ma.l'lt"r S1I'il('"II. A key opcmted isolating' switch is lilted 0. 1 the right hand sid e of the instrument panel. Turn the key to swi lch on the elcctrieal system. To Start the Engine when Cold (normal conditions) I. Turn th c fuel lap on, \erlieal to op<! 11 Ihe lank supply and make sure that the gear lever is in Ihe neutral position. 2. Rai se the decompression kver "A", Fig. 3 and turn the engine seve!';.11 times by hand. When the engine lurns ellsily. removt! the starting hundk' and lower the decompression lever. 3. Press Ihe excess ruel plunger "n". Fig. 3 "in". Opcn throttle lever: in. above idling stop. 4. Press the starler bullon. If the engine does nol fire immedi:llely. (/11 /lui k('('p fhl! . Wllrfl" hUIIOII t!l'pre,ued for IIIfJre Ihall 10 .1·UIIIUll" it should be released and depressed again after a period of 20 St.'Conds. This prevents rapid discharg~ of the batteries. When Ihe engine fires the excess fuel device is autonllltically re-sct. The governor conlrol lever shou ld be set : 11 the intermediate position to allow Ihe engine to warm up quickly, or the engine may be put immediately to work. Do not. however. race the engine :!fler slarting from cold. Normal engine working temperature 1 70°F. to 190 F. Fig. 1. ENGINE CONTROLS A. Oe.:omprusor Lever O. Hand Priming Pump 8. Eltctss F",el Button C. V"'nt Plugs (Fuel Pump) E. Flit"" Vent PI",g (I)

To Start the Engine when Cold (Sub zero) In exceptionally cold weather conditions the engine is readily started by using the ether starting car· bu reHor fitted to the air intake manifold. The container is charged by removing the base and inserl' ing one ether capsule. The base is replaced and the engine is prepared for starting. II is a lso important when operating the engine in near arc ti c conditions to ensure that t he co rrect grade of lubricating oil is used ,Ind the engine crilnkshaft freed by turning several times with the starting handle. I. Place the gear lever in neutral. turn the fuel tap on. pull the ruel cut off control "E' " Fig. 2 out and raise the decompressor lever "A", Fig. 3. 2. Turn the engine seve ml times with the starting handle unlil the engine is quite free . J. Push the fucl cut olfcontrol in[lIl/y and lower the decompressor lever. 4. If exception:tlly cold weather, insert one "e t her" capsule. S. Press in the excess fuel plunger lind nOle that it SlaYS in position. 6. Press the starter button . If the engine docs not slart immediately wait for a short period before again pressing the S larter button and ho ld in the excess fuel plunger until the engine runs smoothly. Should the engine again fail to start repeat the procedure of s taning from cold. NOTE.- Further failure to slart in sub.-zero con· ditions may be: due to the presenL'C of i ce in the IraCtor fuel system . If ice is presenl il is advisable to replenish the enlire fuel system al the first opportunity. I ce forma ti on in the fuel system will, in these cireum- s t:Lnces. be found lit either the fuel filter out lei or !It tne fuel sediment bowl. When the engine ha s sta rted, adjust the radialor blind. check the level orlhe cooling system and run the engine at 11 fast speed to warm up quickly. FIC· ... ETHER CAPSULE CARBURETTOR To Stop the Engine l. Reduce the speed to id ling. a nd adjust lhe radiator blind. 2. Pullihe fud eUI-offconlrol out and hold it jllthi s position until the cngmc stops, then return the control to ils normal position. FIC. S. FUEl TAP A. open/OSitiOn B. Cion polltlon Precaution (Stopping) Always S lOp the engine before Ih e fuel is cxhau:> ted Do not s top the engine by turning the fuel tap " off" or by lifting the dccompressor lever. To restart the Engine when warm If the engine is warm it may be restarted by pressing the sturter button only. It is nOI. however, recommended to start and S top the engine at frequent intervals. The amount of fuel sa\<ed is ve ry sma ll and the c"tlra work imposed on Ihe batteries may result in them becoming comple tely discharged. Pr ecaution (Operoting) Always check the fuel oil and water levels before starting the engine. Adjust the radiator blind control \0 maintain the correct tcmperature. R ecommended Fuels United Kingdom and Overseas Rl"i lish Ist e5 SHELL Dlcsotlle FT"lI~e SH ELL t)iesolitc I)cnmark SH ELL or B. P. Dicsolirn: Norway SHELL Die«)Hnc or M . I. L. B. P, Solarolje S" 'fden SH ELL DldOtineo r S, P. MOl or BranllOlja Nort h and Soulh Rhodesia SH ELL Diesolinc Souill and We5t Afri~ SHELL Dlesolinc PortuguC$C EI~I ArTie. SH ELL Dicsolinc Australia ... SHELL Du:sotinc or C.O.R. India :l nd Pakl.'li"n Soulb Americil Br>l.1':iI and B. P. N.Z. Di cso lcum Burmah-S hcll H.S. D. SH ELL Du::solinc SH ELL-Mc~. Diesel 011

David Brown AD4-25 Diesel Engine Full Service Repair Manual

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