TM 5-4210-227-24&P-3 TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) FOR 85' AERIAL LADDER FIRE FIGHTING TRUCK NSN 4210-00-965-1254 HEADQUARTERS, DEPARTMENT OF THE ARMY 5 NOVEMBER 1986
COMPLETE MANUAL TABLE OF CONTENTS Publication Section Section Title TM 5-4210-227-24&P-1 1 Introduction/Tabulated Data 2 Chassis Assembly 3 Pump Assembly 4 Ladder Assembly 5 Hydraulic System 6 Electrical System 7 Pneumatic System 8 Ladder Calibration and Adjustments 9 Illustrations TM 5-4210-227-24&P-2 General Information 1 Engine (less major assemblies) 2 Fuel System and Governors 3 Air Intake Systems 4 Lubrication System 5 Cooling System 6 Exhaust System 7 Electrical Equipment, Instruments and Protective Systems (Sections 8 through 11 not included) 12 Special Equipment 13 Operation 14 Tune-up 15 Preventive Maintenance, Troubleshooting and Storage TM 5-4210-227-24&P-3 1 General Information 2 Description and Operation 3 Preventive Maintenance 4 General Overhaul Information 5 Disassembly of Transmission 6 Rebuild of Subassemblies 7 Assembly of Transmission 8 Wear Limits and Spring Data TM 5-4210-227-24&P-4 1 Allison Automatic Transmission HT 700 Series Parts Catalog 2 Supplemental Parts Information TM 5-4210-227-24&P-5 1 Drive Line 2 Front Axle 3 Rear Axle 4 Steering System 5 Fuel System 6 Brake System 7 Electrical System 8 Miscellaneous A
COMPLETE MANUAL TABLE OF CONTENTS (Continued) Publication Section Section Title TM 5-4210-227-24&P-5 9 General Information (continued) 10 Installation Instructions 11 Troubleshooting and Service TM 5-4210-227-24&P-7 TM 5-4210-227-24&P-8 General Information 1 Engine (less major assemblies) 2 Fuel System and Governors 3 Air Intake System 4 Lubricator System 5 Cooling System 6 Exhaust System 7 Electrical Equipment, Instruments and Protective Systems 8 Power Take-off and Torque Converter 9 Transmissions (Sections 10 and 11 not included) 12 Special Equipment 13 Operation 14 Tune-up 15 Preventive Maintenance, Troubleshooting and Storage Parts List and Foldouts Tools and Equipment TM 5-4210-227-10 1 Introduction/Tabulated Data 2 Operator's Instructions 3 Operator Maintenance7 4 Illustrations 5 Operator's Manual, Series 92 Engines 6 Operator's Manual, Series V-71 Engines 7 Built-in Parts Book for Detroit Diesel Engines 8 Operator's Manual, Fire Apparatus Chassis B
FOREWORD Descriptions, instructions and parts listing pertaining to the Model QWT 85 are discussed throughout this manual under general headings. Foldout illustrations and schematics are located at the rear of this volume. The foldout format is provided in order that illustrations and schematics may be referred to while the supporting text is being examined and studied. A detailed description is given in the Introduction of each Part of the manual to assist the user in finding the information required to operate or maintain the equipment. Operator's Manual (TM 5-4210-227-10) This manual is designed to provide the information necessary for a fire fighter or mechanic to properly operate the truck, the pump and the ladder. Maintenance Manual (TM 5-4210-227-24&P) This manual contains the information necessary for an experienced mechanic to maintain and repair all facets of the apparatus. Each volume is individually indexed for ease of reference. This manual contains all the information necessary to obtain assemblies and subassemblies or individual parts, required to repair and maintain the fire truck. NOTE The installation manual for Jacobs Engine Brake, Model 71/92 and 71A/92A is presented on the following pages. The second part of this volume consists of a commercial bound manual (HT700F Series Engine Manual). TABULATED DATA. (N/A). i
MAINTENANCE MANUAL SECTION I 1. INTRODUCTION/TABULATED DATA 1.1.1. TM 5-4210-227-24&P, Organizational, Direct Support, and General Support Maintenance Manual for 85' Aerial Ladder Fire Fighting Truck is divided into eight volumes. These eight volumes are further subdivided into specific sections consisting of both Government and commercial literature. TM 5-4210-227-10, Operator's Manual for the Aerial Ladder Fire Fighting Truck is one separate manual consisting of five separate sections. 1.1.2. This volume consists of the Jacobs Engine Brake Manual and 8 sections and is arranged as follows: 1. General Information 2. Description and Operation 3. Preventive Maintenance 4. General Overhaul Information 5. Disassembly of Transmission 6. Rebuild of Subassemblies 7. Assembly of Transmission 8. Wear Limits and Spring Data ii
Installation Manual for Model 71/92 & 71A/92A This Engine Brake is designed for use on the following Detroit Diesel Engine Models: 4-71 8V-71 6V-92 6-71 12V-71 8V-92 6V-71 16V-71 16V-92 It will also fit any 71 or 92 series Detroit Diesel Engine that has the same 4-valve or 2-valve cylinder head design and valve spacing as the Engines listed above.
SCHEMATIC DIAGRAM OF ENGINE BRAKE OPERATION OPERATING DESCRIPTION OF JACOBS ENGINE BRAKE THEORY OF OPERATION - Simply stated. energizing the Engine Brake effectively converts a power producing diesel engine Into a power absorbing air compressor. This is accomplished when desired by motion transfer through a masterslave piston arrangement which opens the cylinder exhaust valves near the top of the normal compression stroke releasing the compressed cylinder charge to exhaust. The blowdown of compressed air to atmospheric pressure prevents the return of energy to the engine piston on the expansion stroke. the effect being a net energy loss since the work done in compressing the cylinder charge Is not returned during the expansion process. EXHAUST BLOWDOWN - Referring to the schematic drawing. exhaust blowdown occurs as follows: 1. Energizing the solenoid valve permits engine lube oil to flow under pressure through the control valve to both the master piston and the slave piston. 2. 011 pressure causes the master piston and Its extension to move down, coming to rest on the injector rocker clevis 3. The injector rocker clevis begins upward travel (as in normal injection cycle) forcing the master piston upward and creating a high pressure oil flow to the slave piston The ball check valve in the control valve Imprisons high pressure oil in the master slave piston system. 4. The slave piston under the influence of the high pressure oil flow moves down momentarily opening the exhaust valve while the engine piston is near Its top dead center position releasing compressed cylinder air to the exhaust manifold 5. Compressed air escapes to atmosphere completing a compression braking cycle METHOD OF DRIVING A VEHICLE EQUIPPED WITH A JACOBS ENGINE BRAKE The proper method of driving a vehicle equipped with a Jacobs Engine Brake will be simple for an operator to learn. Since the Engine Brake Is most effective at rated engine speeds. gear selection Is very Important. Gearing down the vehicle. within the limits of rated engine speed, makes the Engine Brake a more effective retarder. Obviously. maximum retarding occurs with the selection of the lowest gear that prevents exceeding rated engine speed. The Engine Brake kit contains a progressive switch that provides two degrees of engine braking This switch provides the operator with greater flexibility of engine retarding After short practice. drivers will learn the combination of gears that will give the best results over a particular route. 2
ENGINE BRAKE INSTALLATION This manual contains instructions for Engine Brake installation on both 2 valve and 4 valve cylinder head designs The 4 valve instructions are labeled 4 valve and the 2 valve instructions are labeled 2 valve If no heading is shown the instructions are applicable to both. 4-Valve Head 2-Valve Head ENGINE PREPARATION Remove rocker cover and observe cylinder head arrangement. Remove fuel supply and draintubes by loosening nuts on injector and risers on back of cylinder head. 4-Valve Install Jacobs exhaust valve bridges onto bridge guides for right hand exhaust valves. 4-Valve Remove the rocker pedestal hold down bolts and disassemble the rocker pedestals and shafts. Remove right hand exhaust valve bridges (one per cylinder). 4-Valve Adjust exhaust valve bridges as instructed in Detroit Diesel Maintenance Manual. CAUTION LOCK LOCKNUT WITH BRIDGE IN VISE, NOT ON ENGINE Tighten locknut to 20-25 lb ft (27-34 N-m) torque Reassemble the rocker pedestals and shafts. 4-Valve Remove adjusting screws and locknuts from engine bridges and insert them into Jacobs bridges. 3 If the engine is equipped with rocker levers having an oil hole drill boss, remove right hand exhaust rocker.
lever and grind off drill boss as shown The drill boss must be removed so that the Jacobs Brake slave piston will function properly 2-Valve Remove rocker pedestal hold down bolts and disassemble the rocker pedestals and shafts. CAUTION Loosen right-hand exhaust valve push rod locknut as viewed from fuel rack side of cylinder head and rotate rocker lever to provide approximately 1/16" (16 mm) more valve lash This clearance is obtained to accommodate the thickness of the Jacobs valve stem cap when installed. 2-Valve Using the clamping tool from the Jacobs Kit, back off thumb screw Install tool squarely over valve stem cap with Its feet under the exposed coil of valve spring Tighten thumb screw to seat cap Remove Tool Replace rocker shafts and pedestals. 2-Valve If a hexagon cover stud is located near a right hand exhaust valve. replace It with a round Jacobs cover stud which provides the necessary cap clearance Use 1/4" Hex Wrench in threaded hole to tighten stud. 2-Valve On engines equipped with high mount injector clamps remove clamp by removing bolt and special washer Replace with Jacobs high mount clamp and the same washer and bolt IMPORTANT Tighten bolt to 20-25 lb ft (27-34 N-m) The Jacobs clamp can be identified by a small milled section on one side This provides clearance for the exhaust valve stem cap. Assemble Jacobs right and lent hand fuel pipes 2-Valve Install Jacobs valve stem caps on right hand exhaust valves (one per cylinder) Press caps firmly over valve springs Hexagon cover studs must be removed if located near this valve. 4 IMPORTANT Torque fuel pipe nuts to 12 to 15 lb ft (16-20 N m) NOTE: This torque specification is very important and should be strictly adhered to. Over tightening or under tightening may cause fuel pipe failure and engine lube oil dilution Serious engine damage may result Be careful not to contact the fuel pipe with the fuel pipe nut wrench as this may cause damage to the flare.
BRAKE ARRANGEMENT FOR 6 & V-12 Prior to installing units on engine Brake housings should be laid out on work bench in order shown in diagram to match engine configuration Jumper and seal rings (X) should be Inserted into each unit as indicated in diagram. assembly insuring the master piston fork guide assembly is properly located over the injector push rod clevis Torque hold down cap screws to 88-92 lb ft (119-125N m). CAUTION Make certain that fuel pipes do not interfere with the Engine Brake Housing A fuel pipe rubbing on the Engine Brake Housing will cause failure of the fuel pipe and subsequent engine damage may result Insert oil jumper with lock nut attached Screw In approximately 1/2 inch (12. 7 mm) to avoid damage in assembly to engine. Insert and tighten 5/16"-24 plugs on outboard side of end Brake units. Insert lube seal ring. Reposition seal ring if necessary. to insure proper fit into head of oil jumper Back out oil jumper until metal to metal contact Is made with adjacent housing Back off 1/3 turn from contact point to establish working clearance Hold jumper in this position and lock locknut. VALVE AND INJECTOR ADJUSTMENT Adjust valves and time Injectors as instructed In Detroit Diesel Maintenance Manual ADJUSTMENT OF ENGINE BRAKE UNITS To prevent engine damage by piston to valve contact the following Instructions must be followed carefully Prior to making slave piston adjustments Insure exhaust valves are closed and injector Is in delivery position A new Slave Piston setting of.059" has been released to provide for an increase In Engine Brake performance on all 71 and 92 Detroit Diesel series engines. There are two requirements which must be met before the.059" setting can be used 1. The engine rocker brackets must be the latest style with a larger pad area for better engine brake housing support The new bracket was Introduced on all Detroit Diesel series 71 and 92 engine about November, 1977. The part number for this bracket is 5103903 2. The Model 71A/92A engine brake housings (P/N 007077 and 007078) only can be used for the new 059" setting Refer to Jacobs Service Letter 160 for differences in engine brake housings Do not use the.059" setting with the former Detroit Diesel Rocker brackets or with the earlier Model 71/92 engine brake. Engine or engine brake failures will result. Those applications must continue to use the.064" slave piston setting. A Jacobs Feeler Gauge ( 059") has been released The gauge P/N is 007958 and can be obtained from any Jacobs Engine Brake Distributor With engine stopped and exhaust valves closed, insert the 064 (1.6 mm) or the.059 (1. 49 mm) feeler gauge between slave piston foot and exhaust valve bridge Turn adjusting screw in Assemble Jacobs hold down cap screws to brake housing Position housing over rocker and pedestal 5