All 48 pages of this David Brown AD4/47 Repair Manual (OEM #TP 644) target the engine shared by the 990 Implematic Livedrive, 990 Selectamatic Livedrive, 990 Implematic Non-Livedrive, 990 Selectamatic Non-Livedrive, and 990 Industrial Models, across the AD4/47A, AD4/47B, and ID4/47 variants. Inside you get a complete fuel system chapter covering injector servicing, injection pump work, and fuel tank removal; a full lubrication section with oil pump teardown and relief valve specs; plus crankshaft regrinding, cylinder sleeve dimensions, timing gear alignment, and valve mechanism procedures. Exploded views, system diagrams, and a full dimensional data section round it out with torque figures, wear limits, piston measurements, and fluid capacities. Set intake valve clearance to 0.015 in (0.35 mm) on engines through AD4/47A serial 60389, or drop to 0.010 in (0.25 mm) on later builds. Your machine is down. Bookmarked by section and keyword-searchable; pull it up on any device and get to the right spec fast.
What's Inside This David Brown AD4/47 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Maintenance | 5-8 | Air Cleaner, Engine Breather, Valve Clearance, Fan Belt, Fuel Filter, Water Pump |
| Fuel System | 9-15 | Venting the System, Fuel Feed Pump, Injector Servicing, Injection Pump, Fuel Filters, Fuel Tank Removal |
| Lubrication System | 16-19 | Engine Lubrication, Oil Warning Light, Oil Pump, Dismantle Pump, Oil Pump Bracket Bush, Relief Valve |
| Pistons and Connecting Rods | 21-22 | Removing Pistons, Gudgeon Pins, Connecting Rods, Piston Rings |
| Crankshaft and Bearings | 23 | Crankshaft Regrinding, Crankshaft Rear Oil Seal, Main Journal Diameter, Big-End Journal Diameter, Thrust Washer Thickness |
| Cylinder Sleeves | 24 | Removing Sleeves, Rubber Sealing Rings, Sleeve Protrusion, Sleeve Dimensions |
| Timing Gears | 25-26 | Timing Gear Cover, Camshaft Gear Bolt, Intermediate Gear Shaft, Injection Pump Drive Gear, Timing Gear Markings |
| Valve Mechanism | 27 | Camshaft, Valve Rockers, Valve Clearance, Valve Springs, Valve Stem Diameters, Valve Timing |
| Engine Removal | 27-31 | Method 'a', Non-Livedrive Models, Livedrive Models - Six-Speed, Livedrive Models - Twelve-Speed, Method 'b' |
| Dimensional Data | 32-36 | Torque Figures, Capacities, Wear Limits, Piston Dimensions, Valve Clearance, Crankshaft |
| Summary of Design Changes | 37-38 | Crankshaft Components, Valve Train Components, Fuel Injection System Components, Cooling System Components, Electrical System Components, Engine Covers and Gaskets |
| Approved Lubricants and Test Oils | 39-48 | Engine Oil Classification, Sae Viscosity Grading, Api Classification, Service Classifications, Fuel, Grease and Anti-Freeze, Fuel Injection Equipment Test Oils |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| AD4/47A (to serial 60389), AD4/47B (to serial 40724) | ||
| Valve Clearance (set cold) - Inlet (to AD4/47A serial 60389) | 0.015 in (0.35 mm) | p. 33 |
| Valve Clearance (set cold) - Exhaust (to AD4/47A serial 60389) | 0.012 in (0.30 mm) | p. 33 |
| All Models | ||
| Intermediate gear end-float | 0.002-0.004 in (0.05-0.010 mm) | p. 29 |
| Camshaft end-float | 0.010-0.020 in (0.254-0.508 mm) | p. 36 |
| Cylinder sleeve protrusion above block face | 0.002-0.005 in (0.05-0.13 mm) | p. 29 |
| Sleeve Bore (new) | 3.655-3.6250 in (92.088-92.076 mm) | p. 37 |
| Cylinder head nuts and bolts torque (final stage) | 90 lb ft (12.5 kg metres) | p. 25 |
| Main bearing cap bolts torque | 140 lb ft | p. 36 |
| Cooling system capacity | 3 gal | p. 36 |
| Engine lubricating oil capacity | 13 pints | p. 36 |
| AD4/47A (from serial 60390), AD4/47B (from serial 40725) | ||
| Valve Clearance (set cold) - Inlet (from AD4/47A serial 60390) | 0.010 in (0.25 mm) | p. 33 |
| Valve Clearance (set cold) - Exhaust (from AD4/47A serial 60390) | 0.007 in (0.18 mm) | p. 33 |
David Brown AD4/47 Common Problems This Manual Covers
David Brown 990 timing gear marks refuse to align during engine reassembly p. 25
Rotate the crankshaft slowly; timing marks on all three gears align only once in 47 crankshaft revolutions, so work methodically and mark the position before removing old gears. After fitting, verify intermediate gear end-float at 0.002-0.004 in (0.05-0.10 mm) and torque the camshaft gear bolt to 40 lb ft (5.53 kg metres). Full procedure is on page 25.
Manual Section: Timing GearsValve clearances set wrong after timing gear work, engine runs rough at idle p. 33
Check your engine serial number before touching the feeler gauges. On AD4/47A (to serial 60389) and AD4/47B (to serial 40724), set inlet at 0.015 in (0.35 mm) and exhaust at 0.012 in (0.30 mm) cold. Later engines from serial 60390/40725 take 0.010 in inlet and 0.007 in exhaust. Clearance table is on page 33.
Manual Section: Valve MechanismCylinder sleeve protrusion out of spec after replacement, coolant weeps past head gasket p. 24
Measure sleeve protrusion after pressing each sleeve into the block. Confirm protrusion lands between 0.002-0.005 in (0.05-0.13 mm) by inserting a feeler gauge between the locating pad and block face, following the replacement steps on page 24. New sleeves must bore to 3.6550-3.6250 in, with maximum taper and ovality at 0.0005 in (0.0127 mm) each.
Manual Section: Cylinder SleevesInjectors fail bench test, won't hold pressure, engine smokes and misfires under load p. 9
Test each injector on a pressure tester before reinstalling. Setting pressure must hold at 175 atmospheres (1810 kg/cm2); if it drops, disassemble, clean the nozzle and needle, then readjust. Replace any nozzle that still won't hold 175 atmospheres after cleaning. Injector testing and cleaning procedures are covered beginning on page 9.
Manual Section: Fuel SystemOil warning light stays on at operating temperature, pressure confirmed low at idle p. 17
Check oil level and condition first. The relief valve opens at 40 lb/sq. in. (2.8 kg/sq. cm); confirm it seats correctly using the specs on page 17. If pressure stays low with correct oil level, pull the pump from the sump, inspect the gear set for wear, and verify bracket bush clearance before reassembly.
Manual Section: Lubrication SystemReplacement engine block bore is wrong size, piston ring seal fails on startup p. 37
Verify sleeve dimensions before ordering parts; the AD4/47 engine uses wet sleeves with bore of 3.6550-3.6250 in (92.088-92.076 mm). The later 4/55 engine has different bore dimensions entirely, so confirm your serial number before sourcing. Full sleeve specifications, including protrusion and ovality limits, are listed on page 37 under Summary of Design Changes.
Manual Section: Summary of Design ChangesFrequently Asked Questions
How to reset engine timing marks after valve clearance adjustment?
To reset timing marks on the engine, as part of the engine tune-up, check the timing marks on the pump and pump drive housing. If necessary, loosen the mounting nuts and rotate the pump to align the marks. This procedure is performed after checking valve clearances.
Torque
The cylinder head bolts should be tightened in three stages of 30, 60, and 90 lb ft (4, 8, and 12.5 kg metres) following the specified sequence on page 25. The camshaft gear bolt has a torque specification of 40 lb ft (5.53 kg metres).
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