Professional Documents
Culture Documents
Instructions Manual
JU/JW MODEL ENGINES
FOR
FIRE PUMP APPLICATIONS
www.clarkefire.com
MP-7 6/12
C13960 rev Y
CONTENTS
SUBJECT PAGE
1.0 INTRODUCTION 5
1.1 IDENTIFICATION/NAMEPLATE 5
1.2 SAFETY/CAUTION/WARNINGS 6
2.0 INSTALLATION/OPERATION 10
2.1 TYPICAL INSTALLATION 10
2.2 ENGINE STORAGE 11
2.2.1 Storage Less than 1 year 11
2.2.2 Extended Storage Maintenance Procedure 11
2.3 INSTALLATION INSTRUCTIONS 11
2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 13
2.4.1 Listed Driveshaft 13
2.4.2 Driveshaft 13
2.4.3 Other Coupling Types 17
2.5 WEEKLY TEST 17
2.6 STARTING/STOPPING THE ENGINE 17
2.6.1 Special Notes to Equipment Installer of an LPCB Approved (LPS1239) Engine Model 17
2.6.2 To Start Engine 17
2.6.3 To Stop Engine 20
3.0 ENGINE SYSTEMS 20
3.1 FUEL SYSTEM 20
3.1.1 Bleeding the Fuel System 20
3.1.1.1 JU4/6 UF, NL 20
3.1.1.2 JU4/6 LP 21
3.1.1.3 JW6 UF, NL 21
3.1.2 Draining the Condensate from the Fuel Filter 22
3.1.3 Changing Fuel Filter Cartridge 23
3.1.3.1 JU4/6 UF, NL 23
3.1.3.2 JU4/6 LP 23
3.1.3.3 JW6 UF, NL 23
3.1.4 Fuel Tanks 24
3.1.5 JU Fuel Injection Pump Components 24
3.1.6 JW Fuel Injection Pump Components 25
3.2 AIR/EXHAUST SYSTEM 26
3.2.1 Ambient Conditions 26
3.2.2 Ventilation 26
3.2.3 Standard Air Cleaner 26
3.2.4 Crankcase Ventilation 27
Page 2 of 51
3.2.4.1 Open Crankcase Ventilation 27
3.2.4.2 Crankcase Ventilation System 27
3.2.5 Exhaust System 28
3.3 LUBRICATION SYSTEM 28
3.3.1 Checking Sump Oil 28
3.3.2 Changing Engine Oil 29
3.3.3 Changing Oil Filter Cartridge 29
3.3.4 Oil Specification 29
3.3.5 Oil Capacities 30
3.4 COOLING SYSTEM 30
3.4.1 Intended Engine Operating Temperature 30
3.4.2 Engine Coolant 30
3.4.3 Water 30
3.4.4 Coolant Capacities 30
3.4.5 Coolant Inhibitor 31
3.4.6 Procedure for Filling Engine 31
3.4.6.1 Engines without Coolant Recovery Tank 31
3.4.6.2 Engines with Coolant Recovery Tank 32
3.4.7 Providing Raw Water Supply to the Engine Heat Exchanger 33
3.4.7.1 Raw Water Supply 33
3.4.7.2 Cooling Loop 33
3.4.7.3 Setting Raw Water Flow Rate 34
3.4.7.4 Raw Water Outlet 35
3.4.7.5 Raw Water Quality Strainers, Deterioration of Heat Exchanger (CAC) 35
3.4.7.6 Backflow Preventers 35
3.4.7.7 Raw Water Outlet Temperature 35
3.4.7.8 Flow Paths of Engine Cooling System 35
3.5 ELECTRICAL SYSTEM 37
3.5.1 Wiring Diagrams 37
3.5.2 Checking Drive Belt Tension and Adjustment 37
3.5.3 Speed Switch 38
3.5.4 Magnetic Pick-Up 38
3.5.5 Mechanical Engine Control & Alarm Board (MECAB) Speed Switch Troubleshooting 38
3.5.6 Field Simulation of Pump Controller Alarms 40
3.6 ENGINE SPEED ADJUSTMENT 41
4.0 MAINTENANCE SCHEDULE 41
4.1 ROUTINE MAINTENANCE 41
5.0 TROUBLE SHOOTING 42
6.0 PARTS INFORMATION 42
6.1 SPARES 42
Page 3 of 51
6.2 ENGINE MAINTENANCE PARTS LIST 42
7.0 OWNER ASSISTANCE 42
8.0 WARRANTY 42
8.1 GENERAL WARRANTY STATEMENT 42
8.2 CLARKE WARRANTY 42
8.3 JOHN DEERE WARRANTY 43
8.3.1 Warranty Duration 43
8.3.2 Warranty Coverage 43
8.3.3 Emissions System Warranty 43
8.3.4 Obtaining Warranty Service 44
8.3.5 Warranty Extensions 45
8.3.6 Purchaser’s Responsibilities 45
8.3.7 No Representations or Implied Warranty 45
8.3.8 Remedy Limitation 45
8.3.9 No Seller’s Warranty 46
8.3.10 Additional Information 46
9.0 ATCM CALIFORNIA EMISSION REGULATIONS FOR STATIONARY ENGINES 46
10.0 INSTALLATION & OPERATION DATA (See Technical Catalog C13965) 47
11.0 WIRING DIAGRAMS (See Technical Catalog C13965) 47
12.0 PARTS ILLLUSTRATION (See Technical Catalog C13965) 47
13.0 APPENIX (Alpha Index) 47
APPENDIX “A” 47
Check factory availability for a manual in one of the following languages:
NOTE
The information contained in this book is intended to assist operating personnel by providing
information on the characteristics of the purchased equipment.
It does not relieve the user of their responsibility of using accepted practices in the installation,
operation, and maintenance of the equipment.
NOTE: CLARKE FPPG Reserves the right to update the contents of this publication without
notice.
Page 4 of 51
1.0 INTRODUCTION This manual provides all the information necessary to
operate your newly acquired engine safely and
SCOPE OF SUPPLY efficiently, and perform routine servicing correctly.
Please read it carefully.
The following paragraphs summarize the “Scope of
Supply” of the Engine: MODEL NUMBERING & IDENTIFICATION
The CLARKE Engine supplied has been There are two identification plates attached to each
designed for the sole purpose of driving a engine. Clarke Identification Plate: Engine Model,
stationary Emergency Fire Pump. It must not Serial Number, Rating and Date of Manufacture are
be used for any other purpose. shown on this identification plate. The JU Series
identification plate is mounted on the flywheel
Shall not be subjected to Horsepower housing at the rear of the engine. The JW Series
requirements greater than the certified identification plate is mounted on right rear engine
nameplate rating (for UL/cUL/FM/LPCB mount.
only).
Note that there are five types of identification plates,
Engines must be sized to cover fully the dependent on whether the engine is a “Non-Listed”
maximum power absorbed by any particular or “Listed/Approved” Model. These are typical
driven equipment together with a safety examples. (See Figure #1).
factor on no less than 10%. (For Non-listed
only). Clarke Identification Plates
USA Non Listed USA Listed/Approved
Derates for elevation and temperature need to
be considered for maximum pump power.
1.1 IDENTIFICATION/NAMEPLATE
Page 5 of 51
UK Listed/Approved John Deere Serial identification plate is located on
the left-hand side of the engine between the intake
manifold and starting motor. On the JU Series, the
John Deere identification plate is located on the right
side of the cylinder block behind the fuel filter.
1.2 SAFETY/CAUTION/WARNINGS
Page 6 of 51
JU6R-NLAAL7, JU6R-NLAAL9,
JU6R-NLAAL1, JU6R-NLAAM7,
JU6R-NLAAM9, JU6R-NLAAM1,
JU6R-NLAA57, JU6R-NLAA49,
JU6R-NLAA51, JU6R-NLAA53,
JU6R-NLKAD9, JU6R-NLKAD1,
JU6R-NLKA29, JU6R-NLKA31,
JU6R-NLKA33, JU6R-NLKAG7,
JU6R-NLKAL7, KU6R-NLKAL9,
JU6R-NLKAL1, JU6R-NLKAM7,
JU6R-NLKAM9, KU6R-NLKAM1,
JU6R-NLKA57, JU6R-NLKA49,
JU6R-NLKA51, JU6R-NLKA53
JU6R-NLAA67, JU6R-NLAA59,
JU6R-NLAA61, JU6R-NLAAPF,
JU6R-NLAAQ7, JU6R-NLAARF,
JU6R-NLAAS9, JU6R-NLAA83,
1844 (836)
JU6R-NLKA67, JU6R-NLKA59,
JU6R-NLKA61, JU6R-NLKAPF,
JU6R-NLKAQ7, JU6R-NLKARF,
JU6R-NLKAS9, JU6R-NLKA83
JW6H-UF30 (JDFP-06WA),38,NL30 2012 (910)
JW6H-AP30
JW6H-UF40 (JDFP-06WR),48,NL40, 2003 (906)
JW6H-AP40
JW6H-UF50,60,58,H8,NL50, 60, 2053 (929)
JW6H-AP50, 60
JW6H-UFADB0, D0, F0, J0, 70, 80, 2094 (948)
UFAAM8, AA80
Figure #2
Page 7 of 51
GRANGE WORKS, LOMOND ROAD, COATBRIDGE, UNITED KINGDOM, ML5 2NN
DECLARATION OF INCORPORATION
We hereby declare that the engine is intended to be incorporated into other machinery and must not be put into service until the
relevant machinery, into which the engine is to be incorporated, has been declared in conformity with the essential health and
safety requirements of the machinery Directive 98/37 EC and consequently the conditions required for the CE Mark.
We declare that the engine is manufactured in accordance with the following Standards and Directives:
Directive 98/37 EC, 89/336 EEC, 73/23 EEC.
Standards EN 292, Part 1 and Part 2, EN 60204-1
2) The engine has moving parts, areas of high temperatures and high temperature
fluids under pressure. In addition it has an electrical system which may be under
strong current.
3) The engine produces harmful gases, noise and vibration and it is necessary to
take suitable precautionary measures when moving, installing and operating the
engine to reduce risk associated with the characteristics stated above.
4) The engine must be installed in accordance with local laws and regulations. The
engine must not be started and operated before the machinery into which it is to
be incorporated and/or its overall installation has been made to comply with local
laws and regulations. The engine must only be used in accordance with the scope
of supply and the intended applications.
Figure #5
Page 8 of 51
FIRE Wash the eye with running water for
at least 20 minutes, keeping the
Put out the fire using extinguishers recommended by eyelids open so that the water runs
the manufacturer of the machine or the installation. over the eyeball and moving the eye
in all directions.
BURNS
1) Put out the flames on the clothing of the ELECTROCUTION
burns victim by means of:
drenching with water Electrocution can be caused by:
use of powder extinguisher, making
sure not to direct the jets onto the 1) The engine’s electrical system (12/24
face VDC)
blankets or rolling the victim on the 2) The electrical coolant pre-heating system
ground 120/240 Volt AC (if supplied) AC current.
2) Do not pull off strips of clothing that are
sticking to the skin. In the first case, the low voltage does not involve
3) In the case of scalding with liquids, remove high current flows through the human body;
the soaked clothing quickly but carefully. however, if there is a short circuit, caused by a metal
4) Cover the burn with a special anti-burn tool, sparks and burns may occur.
packet or with a sterile bandage. In the second case, the high voltage causes strong
currents, which can be dangerous.
CARBON MONOXIDE POISONING (CO) If this happens, break the current by operating the
switch before touching the injured person.
Carbon monoxide contained in engine exhaust gases
is odorless and dangerous because it is poisonous and If this is not possible, bear in mind that any other
with air, it forms an explosive mixture. attempt is highly dangerous also for the person
assisting; therefore, any attempt to help the victim
Carbon monoxide is very dangerous in enclosed must be carried out without fail using means that are
premises because it can reach a critical concentration insulating.
in a short time.
WOUNDS AND FRACTURES
When attending a person suffering from CO
poisoning in enclosed premises, ventilate the The wide range of possible injuries and the specific
premises immediately to reduce the gas nature of the help needed means that the medical
concentration. services must be called.
When accessing the premises, the person providing If the person is bleeding, compress the wound
the aid must hold his breath, not light flames, turn on externally until help arrives.
lights or activate electric bells or telephones so as to
avoid explosions. In the case of fracture do not move the part of the
body affected by the fracture. When moving an
Take the victim to a ventilated area or into the open injured person permission from that person must be
air, placing him on his side if he is unconscious. received until you can help him. Unless the injury is
life threatening, move the injured person with
CAUSTIC BURNS extreme care and then only if strictly necessary.
Page 9 of 51
Coolant Mixture Air Filter Installation
Lifting Point
2.0 INSTALLATION/OPERATION
Rotating Parts
Page 10 of 51
6) Prepare a container as a fuel source using a
mixture of Mobilarma or Sta-Bil with ONLY
Diesel #2 fuel or “Red” diesel fuel (ASTM
11 D-975) or BS2869 Class A2.
7) Disconnect the coupling or drive shaft from
the pump.
8) Start and run the engine at a slow speed for
1-2 minutes being careful not to exceed the
normal operating temperature.
Figure #6A 9) Drain the oil and coolant.
Typical Installation 10) Replace the protective plugs that were used
Radiator Cooled Engine for shipping and storage.
11) Attach to the engine a visible card, specifying
For radiator cooled engines, the total air supply path “ENGINE WITHOUT OIL” DO NOT
to the pump room, which includes any louvers or OPERATE”.
dampers, shall not restrict the flow of the air more
than 0.2” (5.1mm) water column. Likewise, the air IMPORTANT: THIS TREATMENT MUST BE
discharge path, which includes any louvers, dampers, REPEATED EVERY 6 MONTHS
or ducting, shall not restrict the flow of air more than ************************
0.3” (7.6mm) water column. PUTTING ENGINE INTO SERVICE AFTER
ADDITIONAL PRESERVATION SERVICE:
2.2 ENGINE STORAGE To restore the normal operation running conditions of
the engine, carry out the following:
2.2.1 Storage less than 1 year
1) Fill the engine sump with the normal
Storing engines requires special attention. Clarke recommended oil, to the required level.
engines, as prepared for shipment, may be stored for 2) Remove the protective plugs used for
a minimum of one year. During this period, they shipping and storage.
should be stored indoors in a dry environment. 3) Refill cooling water to proper level.
Protective coverings are recommended provided they 4) Remove the card “ENGINE WITHOUT OIL,
are arranged to allow for air circulation. The stored DO NOT OPERATE”.
engine should be inspected periodically for obvious 5) Follow all steps of the Installation
conditions such as standing water, part theft, excess Instructions when the engine will be put into
dirt buildup or any other condition that may be service.
detrimental to the engine or components.
Any such conditions found must be corrected 2.3 INSTALLATION INSTRUCTIONS
immediately.
The correct installation of the engine is very
2.2.2 Extended Storage Maintenance Procedure important to achieving optimum performance and
extended engine life.
After a one year storage period or if the engine is
being taken out of service for more than 6 months, In this respect, the engine has certain installation
additional preservation service must be performed as requirements, which are critical to how it performs.
follows: These requirements are generally associated with the
cooling, exhaust, induction air, and fuel systems.
1) Drain the engine oil and change the oil filter.
2) Refill the engine crankcase with MIL-L- This section of the manual should be read in
21260 preservative oil. conjunction with the relevant Installation and
3) Change the fuel filter. Operation Data Sheets. If there is any doubt about an
4) Install the coolant plugs and install coolant in installation, contact should be made with Clarke
the normal mix percentage of 50% coolant, Customer Support giving exact details of the
50% water, premixed. problem.
5) Remove the protection from the intake and
exhaust openings.
Page 11 of 51
All installations should be clean, free of any debris the outlet connection on the heat exchanger.
and dry. Care should be taken to ensure that there is Discharge water piping should be installed in
easy access to the engine for maintenance and repair. accordance with applicable codes. All
The safety of personnel who may be in the area of the plumbing connecting to the heat exchanger
engine when it is running is of paramount importance must be secured to minimize movement by
when designing the installation layout. the engine. Cooling loop water pressure to
1) Secure pump set to foundation and complete the heat exchanger must not exceed the limit
installation in accordance with pump that is stated on the heat exchanger supplied
manufacturer’s instructions. Perform engine- with the engine.
to-pump coupling alignment. Lubricate Falk 2b) Engine with Radiator Cooling:
coupling with supplied grease or driveshaft Connect radiator air discharge ducting to
universal joints with NLGI grade #1 or #2 radiator duct flange. Discharge ducting
grease at the (3) Zerk fittings. (Refer to should be installed in accordance with
section 2.4 for specific alignment applicable codes. A flexible duct section
instructions). should be provided to isolate engine from
2a) Engine with Heat Exchanger Cooling: building.
Install the heat exchanger discharge pipe. 3) Install all engine cooling system draincocks
The discharge pipe should be no smaller than and plugs.
Engine
Qty Description Location Model
1 1/8” Water Heater JU4/6H,
draincock inlet tube JU4/6R
1 1/8” Coolant heater JDFP,
draincock inlet tube JW6
1 Plug Oil Cooler JU4/6H,
RE46686 JU4/6R
1 3/8” pipe plug Heat exchanger JDFP,
JW6
1 Electrode Bottom of heat JU4/6H
plug exchanger
4) Fill engine cooling system with premixed tested for use with only No. 2-D diesel
50% water / 50% coolant solution. Use only fuel conforming to ASTM D-975.
coolants meeting ASTM-D6210 Additionally, in European countries an
specifications for heavy-duty diesel engines. acceptable alternative fuel is “red” diesel
Never use light-duty or automotive coolants
fuel conforming to BS2869 Class A2.
in the engine that are stated as ASTM-D3306
only. Refer to Figure #34 in section 3.4.3
Both of these fuel specifications must
for cooling system capacity. Refer to section contain NO (0%) bio-fuel. Fuel supply
3.4.5 for filling procedure. level must meet applicable code
5) Engine is shipped with oil installed. For requirements. Do not use a copper based or
make-up oil specification refer to section 3.3 galvanized material for any component of a
Lubrication System. diesel fuel system. The fuel will chemically
6) Connect fuel supply and return line to fuel react with the zinc resulting in clogged fuel
supply tank plumbing. Reference the Fuel filters and injector systems.
System section of the Installation and 7) Remove protective covering on air cleaner
Operation Data in the Technical Catalog, for element.
piping size, maximum allowable fuel pump 8) Connect jacket water heater (if supplied) to
suction, and maximum allowable fuel head AC power source. For JU4/6 Series the
requirements. Fill supply tank with ONLY electrical supply requirements are indicated
#2 diesel fuel (ASTM D-975) or BS 2869 on the heater body. Connect the supplied
Class A2 “Red” diesel fuel, bleed supply heater connection wire directly to a customer
system of air and check for leaks. supplied electrical junction box. For
JDFP/JW6 Series the electrical supply
CAUTION: All diesel fire pump drivers
requirements are indicated on the connection
manufactured by Clarke are designed and
Page 12 of 51
box. Connect to the heater directly to the 12) Always follow fire pump controller operating
junction box at the end of the heater only. instructions when switching on/off battery
Supply wiring should never be routed chargers and disconnecting/reconnecting
through the engine gauge panel. Severe batteries from engine.
damage to critical engine control components 13) Note: Clarke Operation and Maintenance
could result. Energize heater only after step Instructions Manual and Clarke parts
#4 is completed. illustration pages are located inside the
9) Connect exhaust system to flexible engine gauge panel.
connection on the engine. The exhaust 14) IMPORTANT! In order to obtain prompt
system plumbing must be supported by the Warranty Service and to comply with
building structure and not the engine. The Emissions Regulations, this engine must be
exhaust flexible connection is provided only registered to the final installation name and
for the purpose of thermal expansion and address. To register this engine, go to
vibration isolation, not for misalignment or www.clarkefire.com and select Warranty
directional change. Registration.
10) Make electrical DC connections between the
engine gauge panel terminal strip (if 2.4 SPECIFIC FLYWHEEL COUPLING
supplied) and the controller per the controller ALIGNMENT INSTRUCTIONS
manufacturer’s instructions. Refer to the
wiring diagram sticker located on the inside 2.4.1 Listed Driveshafts
cover of the engine gauge panel for proper Refer to Listed Driveshaft Installation,
connection of the water solenoid. Operation and Maintenance Manual
11) Fill batteries with electrolyte per battery C132355
manufacturer’s instructions. Connect cables
between engine and batteries only after 2.4.2 Driveshaft
electrolyte is installed. Refer to the wiring
diagram inside the engine gauge panel cover To check the alignment of the pump shaft and engine
(if supplied), or appropriate wiring diagram crankshaft centerlines for proper Parallel Offset and
in the Technical Catalog C13965, for correct Angular tolerance, the driveshaft must be installed
positive and negative connections. Connect between the flywheel drive disc (no drive disc on
negative cables directly to the brass ground JW6 models) and the flanged hub on the pump shaft.
bolt, as indicated with tag C133445. On
JU4/6 Series connect each positive cable to Before removing the driveshaft guard, disconnect the
the large electrical post of the starter motor negative battery cable from both batteries.
as indicated with tag C133443. Note: the
JU4/6 Series have a separate starter motor for Before beginning the alignment checks and making
each battery set. On the JDFP/JW6 Series any necessary corrections, install the driveshaft and
connect each positive cable to the large outer re-torque all driveshaft connection bolts to the values
post of the manual starting contactors as given in the following table:
indicated with tag C133443.
Page 13 of 51
UFAEA9
JU4H-
28,30,32,34,
40, 42, 44,
50,52,54,
H8,H0,H2, 1/2-20 75 - 82.5
58, 84, SC55 Grade 8 (102 – 112)
UFAEE8, SC55A (Hi-
UFAEF2, Tensile)
UFADJ8,
UFADJ2,
UFADHG,
JU4R-
UF40,49,51
,53,
UFAEE7,
F1
JU6H-
UFDO, D2, 90 - 99
30, 32, 34, M12,Class (122 – 134)
G8, M8, M0 SC2130 or 10.9 (see note #1)
SC2130A
M2,58,50, (Metric)
or
52, 54 SC55L-A (Hi- 86 – 94
JU6H- Tensile (117 - 128)
UFABL8, (see note #2)
L0, L2, 76,
90 - 99
M12,Class (122 – 134)
JU6H- SC2130 or 10.9 (see note #1)
UF68, 60, SC2130A or (Metric)
SC61L-A
62, 84, (Hi- 86 – 94
Tensile (117 - 128)
(see note #2)
90 - 99
M12,Class (122 – 134)
All JW6 SC2130A or 10.9 (see note #1)
SC81A (Metric) 86 – 94
(Hi- (117 - 128)
Tensile) (see note #2)
JU6H- M12,Class 90 - 99
UFAAQ8, 10.9 (122 – 134)
KAQ8, (Metric) (see note #1)
AARG, SC81A (Hi-
KARG, Tensile 86 – 94
AAPG, (117 - 128)
KAPG, (see note #2)
AAS0
KAS0
Page 14 of 51
Note 1 – It is recommended that a medium strength
threadlocker (i.e. Loctite – blue #64040) be used in The following steps describe the proper way to check
the assembly and torquing of all hardware. This may alignment. A small pocket scale or ruler with
be purchased as part number 23509536. millimeter markings is recommended to make all
measurements.
Note 2 – 4 of the hi-tensile bolts and/or nuts, that are A) To check the Horizontal Parallel Offset, the
used to connect the driveshaft to the drive disc (all driveshaft must be in the proper orientation.
JU6 models) or flywheel (all JW6 models) and that 1. Rotate the shaft so the reference “AB” on the
connect the driveshaft to the pump companion flange, flywheel disc or the circumference of the
will require a “crow’s foot” wrench attached to a drive shaft flange (against the flywheel) is in
standard torque wrench in order to apply the required the 12 o’clock position shown on figure# 7.
tightening torque. A standard socket will not work 2. Measure from the rear face of the flywheel
due to close proximity of the bolts and/or nuts with drive disc or the drive shaft flange to point A.
the driveshaft yoke. The tightening torque values (Point A is on the bearing bore as shown in
listed for these bolts and/or nuts have been corrected Figure 7, on the instrument panel side of the
for using a “crow’s foot” adapter which extends the engine). This measurement must be:
standard torque wrench’s length.
B) With the driveshaft in the same orientation as the engine). This measurement must be equal to
previous step (Step A), check the Horizontal the measurement at point A + 1 mm.
Angular alignment of the shafts. C) To check the Vertical Parallel Offset, the
1. Measure from the front face of the drive shaft driveshaft must be re-orientated.
flange on the pump end to point B. (Point B 1. Rotate the shaft 90○ so the reference “CD” on
is the bearing bore on the exhaust side of the the flywheel drive disc or the circumference
Page 15 of 51
of the drive shaft flange (against the (Point C is the same as point A with the
flywheel) is in the position shown on driveshaft rotated 90°). The measurement
Figure#8. must be:
2. Measure from the rear face of the flywheel
drive disc or the drive shaft flange to point C.
Figure #7
Page 16 of 51
2) The plant room ventilation ducts are open
and the engine has good access for air.
3) All the guards are in position and, if not, for
whatever reason, any rotating parts will be
free and clear without restriction.
4) Battery covers are in place and there is
nothing on top of or touching the engine,
which is not part of the original supply
specification.
5a) Heat Exchanger Cooling: The water supply
for coolant is available again without
restriction.
5b) Radiator Cooling: The air supply for cooling
Figure #8
is available again without restriction.
DRIVESHAFT MAINTENANCE
When engine is running make sure that the coolant
temperature and oil pressure raw cooling water flow
1. To service the driveshaft disconnect the
are within the limits specified on the relevant
negative battery cables, remove the top of
Installation & Operation Data Sheet in the Technical
guard and set aside.
Catalog, C13965.
2. Rotate engine shaft manually so the u-joint
grease fittings are accessible.
If the coolant temperature is excessive, check:
3. Using a hand held grease gun with N.L.G.I.
a) Cooling loop strainers
grade 1 or 2 grease position on grease fitting.
b) Proper functioning of thermostat
Pump with grease until grease is visible at all
c) Condition of heat exchanger tube bundle
four cap seals.
4. Verify all driveshaft connecting bolts remain
2.6 STARTING/STOPPING THE ENGINE
tight. Re-torque per 2.4.1 if necessary.
5. Reinstall top of guard and connect negative
2.6.1 Special Notes to Equipment Installer of an
battery cables.
LPCB Approved (LPS1239) Engine Model:
2.4.3 Other Coupling Types
Any device fitted to the engine or controller, which
Consult Factory or Clarke website at
could prevent the engine starting automatically, shall
www.clarkefire.com for additional
return automatically to the normal position after
information.
manual application. The electrical fuel shutoff
actuator shall be connected to an Engine Stop button
2.5 WEEKLY TEST
on the main pump controller.
It is recommended that the engine be tested weekly as
The main pump controller shall de-energize the start
allowed by local jurisdictions. An experienced
motor when the engine has achieved 700-1000 rpm.
operator should be present during the
weekly test.
2.6.2 To Start Engine:
NOTE: This engine is designed to operate at rated
Use main pump controller for starting. Follow
load conditions. For testing purposes the engine can
instructions provided by controller manufacturer.
be run at lower load (lower flow) conditions.
Running times in any one period should not exceed
On UL/FM engines, use main pump controller for
30 minutes maximum.
starting and stopping the engine. Should the main
pump controller become inoperable, the engine can
Before starting the engine make sure of the
be manually started and stopped from the engine
following:
gauge panel. For manual starting and stopping of an
engine with a gauge panel: Position MODE
1) The operator has free access to stop the
SELECTOR to MANUAL RUN. (Refer to Figure
engine in an emergency.
#9). Lift and hold MANUAL CRANK #1, until
Page 17 of 51
engine starts, or release after 15 seconds. If unit fails be manually started from the engine gauge panel.
to start, wait for 15 seconds, use MANUAL CRANK For manual starting of an engine with a gauge panel.
#2 and repeat step. If COOLING WATER is not (Refer to Figure #9A): Lift and hold MANUAL
flowing or engine TEMPERATURE is too HIGH, CRANK #1, until engine starts, or release after 15
open cooling system manual by-pass valves (applies seconds. If unit fails to start, wait for 10 seconds, use
to heat exchanger cooled engines only). MANUAL CRANK #2 and repeat step. If
Note: On JW Engines you can also start engines COOLING WATER is not flowing or engine
using manual starting contactors. TEMPERATURE is too HIGH, open cooling
On LPCB engines, use main pump controller for system manual by-pass valves (applies to heat
starting and stopping the engine. Should the main exchanger cooled engines only).
pump controller become inoperable, the engine can
2
UL/FM Front Opening Instrument Panel
1
5
7
4
Figure #9
Page 18 of 51
Non-Listed Instrument Panel
Figure #9A
1
2
1 – Emergency Operating Instructions
2 – Manual Crank Controls
IMPORTANT: Main pump controller selector If engine is started from engine gauge panel: Return
should be in the OFF position when starting from MODE SELECTOR switch to
engine gauge panel. Be sure to return selector on AUTOMATIC/MANUAL STOP position, engine
main pump controller and engine gauge panel to will stop. Close cooling system manual by-pass
AUTOMATIC after completing manual run. valve if opened.
Page 19 of 51
Engines not equipped with an engine gauge panel, 4) Start engine and check for leaks.
and LPCB engines, have a manual shutdown lever
on the engine for shutdown.
B
Figure # 12
Figure #10
If engine will not start, it may be necessary to bleed
Whenever the fuel system has been opened up for air from fuel system at fuel injection pump or
service (lines disconnected or filters removed), it will injection nozzles as explained next.
be necessary to bleed air from the system.
1) Loosen the air bleed vent screw (A) two full 1) Slightly loosen fuel return line connector (A)
turns by hand on fuel filter base. Ref. Figure at fuel injection pump. Ref figure #13
#11 2) Operate fuel supply pump primer lever until
2) Operate supply pump primer lever (B) until fuel, without air bubbles, flows from fuel
fuel flow is free from air bubbles. Ref. return line connection.
Figure #12. 3) Tighten return line connector at 16N-m (12
3) Tighten bleed plug securely; continue lb-ft).
operating hand primer until pump action is 4) Leave hand primer in the inward position
not felt. Push hand primer inward (toward toward cylinder block. Ref. Figure #14.
engine) as far as it will go.
Page 20 of 51
1) Drain water and contaminants from clear
sediment bowl.
2) Loosen air bleed vent screw (A) on fuel filter
A base (Figure# 15)
3) Operate and primer (B) until fuel flow is free
from air bubbles (Figure#15)
4) Tighten vent screw as hand primer is held in
downward pumping position.
Figure # 13
Figure # 15
Page 21 of 51
A
A
D
B B
A
C
If engine will not start, it may be necessary to bleed 3.1.2 Draining the Condensate from the Fuel Filter
air from fuel system at injection nozzles as explained
below. Drain the condensate from the fuel filter. Fuel filters
have a drain (B) located at the bottom of their body
At Fuel Injection Nozzle (A) figure#20, these filters should be drained each
week to relieve built up water.
1) Loosen fuel line connection at no. 1 injection
nozzle (A) (figure#18)
2) Crank engine with starting motor (but do not
start engine), until fuel free from bubbles
flows out of loosened connections. Retighten
connection.
3) Start engine and check for leaks.
4) If engine does not start, repeat procedure at
remaining injection nozzles (if necessary)
until enough air has been removed from fuel
A
system to allow engine to start.
B
Figure #20
Page 22 of 51
3.1.3 Changing the Fuel Filter Cartridges 8) Install retaining ring onto mounting base
making certain dust seal is in place on filter
Changing the cartridges and bleed any air from the base. Hand tighten ring (about 1/3 turn) until
fuel system as per instructions given in section 3.1.1. it “snaps” into the detent. DO NOT over
Fuel filter changes should take place as per tighten retaining ring.
recommendations and only using approved filters. It
may also be necessary to change filters out with the Note: The proper installation is indicated when a
recommendations in the event of: “click” is heard and a release of the retaining ring is
felt.
1) The engine has had an overhaul.
2) The quality of the fuel is questionable. A plug is provided with the new element for plugging
3) The engine has been subjected to temporary the used element.
adverse conditions outwith it normal
operating parameters. 9) Open fuel shut-off valve and bleed the fuel
4) The fuel tank condensation trap has not been system. Tighten bleed plug (D). Reference
drained in line with manufacturer’s Figure #21
recommendations.
Note: Raised locators on fuel filter canister must be 3.1.3.3 JDFP/JW6 Engine Series
indexed properly with slots in mounting base for
correct installation. Each engine has two fuel filters. For the purpose of
identity, the primary filter incorporates the
6) Install new filter element onto mounting transparent water separator.
base. Be sure element is properly indexed
and firmly seated on base. It may be Replacing (round) Primary Fuel Filter/Water
necessary to rotate filter for correct Separator
alignment.
1) Close fuel shut-off valve at bottom of fuel
If equipped with water separator, remove filter tank, if equipped.
element from water separator bowl. Drain and clean 2) Thoroughly clean fuel filter/water separator
separator bowl. Dry with compressed air. Install assembly and surrounding area.
water separator bowl onto new element. Tighten
securely. Note: Lifting up on retaining ring (F) as it is rotated
helps to get it past retaining dent. Ref. Figure #22
7) Align keys on filter element with slots in
filter base.
Page 23 of 51
3) Rotate retaining ring counterclockwise ¼ Note: Keep a small container under drain plug to
turn. Remove ring with filter element. catch draining fuel.
4) Remove water separator bowl (G) from filter
element (E). Drain and clean separator bowl. 3) With fuel filter firm against base, lift up on
Dry with compressed air. Ref. Figure #22 top retaining spring and pull down on bottom
Note: Notice raised locators on filter element. These retaining spring. Pull fuel filter off guide
locators insure proper alignment of filter element to pins of fuel filter base and discard.
filter base. 4) Install new fuel filter onto guide pins of fuel
5) Install water separator bowl onto new filter filter base. Hold filter firmly against base.
element. Tighten securely. 5) Secure bottom filter retaining spring first,
6) Index filter element until longer, vertical then secure top retaining spring (four
locator (D) is oriented opposite mounting arrows).
base. Insert filter element into base securely. 6) Install new drawn plug, shown installed.
It may be necessary to rotate filter for correct Tighten bleed plug and drain plug securely.
alignment. Ref. Figure #22 Do not over tighten.
7) Install retaining ring to filter base, making 7) Open fuel shut-off valve and bleed the fuel
certain dust seal (C) is in place on filter base. system. Ref. Figure #23
Tighten retaining ring until it locks into
detent position and a “click” sound can be
heard. Ref. Figure #22
8) Bleed fuel system.
C
Figure #23
Replacing (rectangular) Secondary Fuel Filter 3.1.5 JU4/6 Fuel Injection Pump Components
Element
THIS TAG IS SUPPLIED ON ALL JU4 AND JU6
1) Close fuel shut-off valve at bottom of fuel ENGINES
tank, if equipped.
2) Loosen bleed plug (C) on side of filter base.
Remove drain plug (B) to drain from fuel
filter. Ref. Figure #23
Page 24 of 51
JU4H-UF30
JU4H-UF40
JU4R-UF40
JU4H-UF50
JU4H-UFH8 20357
JU4H-UFH0
JU4H-UF58
JU4R-UF49
JU4H-LP50
JU6H-UF30
JU6H-UFD0
JU6H-UFG8
JU6H-UFABL0
The above tag is stamped to identify the “As JU6H-UFABL2
JU6H-UFABL8
Built” Components. Refer to the next two tables JU6H-UFM8
to identify: JU6H-UFM0
Table 1) Droop Spring Part Number by Engine JU6H-UF58
JU6H-UF50
Model and Speed. JU6H-UF68
Table 2) Run-Stop Solenoid (Internal to Injection JU6H-UF60 13558
Pump) Part Number by engine voltage. JU6H-UFAAQ8
JU6H-UFAARG
Injection Pump JU6H-UFKAQ8
JU6H-UFKARG
“Droop Spring” Part Number JU6H-UFAAPG
JU6H-UFKAPG
RPM 1760 2350 2800 JU6H-UFAAS0
2100 2600 2960 JU6H-UFKAS0
2350 3000 JU6H-LP50
MODEL JU6H-LP60
JU4H-UF10 JU6H-UF32
JU4R-UF09 JU6H-UFD2 13563
JU4R-UF11 JU6H-UFM2 or
JU4H-UF20 JU6H-UF52 C02353
JU4R-UF19 JU6H-UF62
JU4R-UF21 13563 JU6H-UF34
JU4H-LP20 or JU6H-UF54 24339
JU4R-UF23 C02353 JU6H-UF84
JU4H-UFADJ8 JU6H-UFAB76
JU4H-UFADJ2
JU4H-UFAEA0
JU4H-UFAEE8
Run-Stop Solenoid Part Number
JU4H-UFAEF2
JU4R-UFAEA9 ETR ETS
JU4R-UFAEE7 12 Volt SD26214 or SD26921 or
JU4R-UFAEF1
C07853 C07827
JU4R-UF13
JU4H-UF14 24339 24 Volt SD26387 or SD26922 or
JU4H-UF24 C07826 C07828
JU4H-UFAB26 Legend:
JU4H-UF12 ETR – Energized to Run
JU4H-UF22
JU4H-UF32 13563 ETS – Energized to Stop
JU4H-UF42 or SD # - Stanadyne Part Number
JU4R-UF51 C02353 C # - Clarke Part Number
JU4H-UF52
JU4H-UFH2
3.1.6 JW6 Fuel Injection Pump Components
JU4H-UF34
JU4H-UF44
JU4H-UF54 For Droop Spring and Run-Stop Solenoid (external to
JU4R-UF53 24339 Injection Pump) part numbers consult factory.
JU4H-LP54
JU4H-LPL4
JU4H-UF84
Page 25 of 51
3.2 AIR/EXHAUST SYSTEM
3.2.2 Ventilation
Page 26 of 51
Figure #24
Figure #27 (JDFP/JW6H)
3.2.4 Crankcase Ventilation
3.2.4.2 Crankcase Ventilation System
3.2.4.1 Open Crankcase Ventilation (Refer to figure
A crankcase ventilation system allows for the
#27b)
recirculation of vapors (expelled through a vent pipe
Vapors which may form within the engine are
attached to the rocker cover breather element) to the
removed from the crankcase and gear train
combustion air inlet. Refer to figure 27a.
compartment by a continuous, pressurized ventilation
system.
Figure #27a
Page 27 of 51
JU4R-UF51 to Installation & Operating Data in Technical Catalog
JU4H-UF52 C13965 for exhaust data.
JU4H-UF58
JU4H-UFH2
JU4H-UFH8 The installation of the exhaust system should consist
JU4H-UFH0 of the following:
JU4H-UFADJ8 Personnel protection from hot surfaces.
JU4H-UFADJ2
JU4H-UFADHG Adequate supports to prevent strain on the
JU4H-UFAEA0 engine exhaust outlet and minimize
JU4H-UFAEE8 vibration.
JU4H-UFAEF2 Protection against entry of water and other
JU4R-UFAEA9
JU4R-UFAEE7 foreign matter.
JU4R-UFAEF1
JU6H-UF30 While the engine is running inspect exhaust pipe
JU6H-UF32 outlet outside of the pump room itself for
JU6H-UF50
environmental hazards such as excessive smoke
JU6H-LP50
JU6H-UF52 conditions. The following could be used as a guide
JU6H-UF58 for general engine operating conditions.
JU6H-UF62
JU6H-UF68 1) Blue Smoke – Possible engine oil
JU6H-UF60
JU6H-LP60 consumption.
JU6H-UFD0
JU6H-UFG8 2) White Smoke – Possibility of water in
JU6H-UFABL0 cylinders, water in fuel or internal engine
JU6H-UFABL2
problem.
JU6H-UFABL8
JU6H-UFM8
JU6H-UFM0 Standard Optional 3.3 LUBRICATION SYSTEM
JU6H-UFD2
JU6H-UFM2 3.3.1 Checking Sump Oil
JU6H-UFAARG
JU6H-UFAAQ8
JU6H-UFKARG Check the sump oil level using the dipstick on the
JU6H-UFKAQ8 engine as shown in Figure #28 &29.
JU6H-UFAAPG This level must always be between the dipstick marks
JU6H-UFKAPG
Min. and Max. with the engine not running.
JU6H-UFAAS0
JU6H-UFKAS0
JU4H-UF34
JU4H-UF44
JU4H-UF54
JU4R-UF53
JU4H-LP54
JU4H-LPL4
JU4H-UF84
JU6H-UF34
JU6H-UF54
JU6H-UF84
JU6H-UFAB76
Figure #27b
Figure #28
3.2.5 Exhaust System JU4/6
Page 28 of 51
9. Operate the engine and check for leakage
from the filter. When the engine has cooled,
check the oil level on the dipstick and put
more oil into the sump, if necessary.
10. Return the unit back into service by returning
the main pump controller selector to
“automatic” position and the manual
operating lever to AUTO-OFF position.
Figure #29
JDFP/JW6
Page 29 of 51
Prevent formation of scale or sludge deposits
in the cooling system.
Be compatible with engine hose and seal
materials.
Provide adequate freeze and boil over
protection.
WARNING
A water and anti-freeze solution is required for
pump installations. Premixing this solution prior
Figure #31 to installing is required. This prevents possible
pure anti-freeze chemical reactions to block
3.3.5 Oil Capacities (Including Filter) heater elements which can burnout the element.
ENGINE OIL CAPACITY Please see the technical data section for proper
MODEL QUARTS (LITERS) cooling system capacities of each model.
JU4 – All Models 15.5 (14.7)
JU6 – All Models (except 21.1 (20.0) 3.4.3 Water
JU6H-UFAARG, KARG,
AAPG, KAPG, AAS0,
Water can produce a corrosive environment in the
KAS0, AAQ8, KAQ8)
JU6H-UFAARG, KARG, 34.3 (32.5)
cooling system, and the mineral content may permit
AAPG, KAPG, AAS0, scale deposits to form on internal cooling surfaces.
KAS0, AAQ8, KAQ8 Therefore, inhibitors must be added to control
JW6 – All Models 30.1 (28.5) corrosion, cavitation, and scale deposits.
Figure #32
Chlorides, sulfates, magnesium and calcium are
3.4 COOLING SYSTEM among the materials which make up dissolved solids
that may cause scale deposits, sludge deposits,
3.4.1 Intended Engine Operating Temperature corrosion or a combination of these. Chlorides
and/or sulfates tend to accelerate corrosion, while
The JU and JW engines are provided with either a hardness (percentage of magnesium and calcium salts
heat exchanger or radiator to maintain the engine broadly classified as carbonates) causes deposits of
coolant temperature within recommended operating scale. Water within the limits specified in figure #33
guidelines. is satisfactory as an engine coolant when properly
inhibited. Use of distilled water is preferred.
The JU4H, JU6H, and JW6H have an intended
engine operating temperature of 160º F (71ºC) to Grains
185º F (85º C). A high coolant temperature switch is Parts per per
provided to indicate a high coolant temperature alarm Materials Million Gallon
at 205º F (96º C). Chloride (Max.) 40 2.5
Sulfates (Max.) 100 5.8
3.4.2 Engine Coolant Total Dissolves Solids
(Max.) 340 20
The following information is provided as a guide for Total Hardness (Max.)
John Deere Engine users in the selection of a suitable 170 10
coolant. Figure #33
Page 30 of 51
A 50% coolant water solution is recommended. A controls and prevents scale. These inhibitors are
concentration over 70% is not recommended because available in various forms, such as liquid packages or
of poor heat transfer capability, adverse freeze integral parts of anti-freeze.
protection and possible silicate dropout.
Concentrations below 30% offer little freeze, boil It is imperative that supplemental inhibitors be added
over or corrosion protection. to all John Deere engine systems. A pre-charge
dosage must be used at the initial fill and the
IMPORTANT maintenance dosage used at each service interval.
Never use automotive-type coolants (such as those Serious damage will occur unless inhibitors are used.
meeting only ASTM D3306 or ASTM D4656). Some of the more common corrosion inhibitors are
These coolants do not contain the correct additives borates, nitrates and silicates.
to protect heavy-duty diesel engines. They often Inhibitors become depleted through normal
contain a high concentration of silicates and may operation; additional inhibitors must be added to the
damage the engine or cooling system. coolant as required to maintain original strength
ENGINE COOLANT CAPACITY levels. Refer Figure #35 for proper concentrations of
MODEL QUARTS (LITERS) inhibitors.
JU4H naturally aspirated, 15.3 (14.5) Min. Max
low speed (<2600 rpm) PPM PPM
JU4H naturally aspirated, 15.9 (15)
Boron (B) 1000 1500
high speed (>2600 rpm)
JU4H turbocharged, low 15.3 (14.5)
Nitrite (NO2) 800 2400
speed (<2600 rpm) Nitrates (NO3) 1000 2000
JU4H turbocharged, high 14.8 (14) Silicon (Si) 50 250
speed (>2600 rpm) Phosphorous (P) 300 500
JU4R naturally aspirated, 19.0 (18.0) PH 8.5 10.5
low speed (<2600 rpm) Figure #35
JU4R naturally aspirated, 19.6 (18.5)
high speed (>2600 rpm) Do not use soluble oils or chromate inhibitors in John
JU4R turbocharged, low 20.0 (19.0) Deere engines. Detrimental effects will occur.
speed (<2600 rpm)
To properly check inhibitor concentrations it may be
JU4R turbocharged, high 19.5 (18.5)
speed (>2600 rpm)
necessary to contact your local Service/Dealer for
JU6H low speed (<2600 19.5 (18.5) assistance. Refer to Parts Information Section to
rpm) obtain the part number for the factory Coolant
JU6H high speed (>2600 20.0 (19.0) Analysis Kit. This kit can be purchased for a
rpm) nominal fee for analyzing the conditions of the
JDFP-06WA/JW6-F30,38 engine’s coolant.
UFADB0, D0, F0, J0, 70, 22 (21)
80, AA80 3.4.6 Procedure for Filling Engine
JDFP-06WR/JW6- 23 (22)
UF40,48, 50, 58, 60, H8 During filling of the cooling system, air pockets may
Figure #34 form. The system must be purged of air prior to
being put in service. This is best accomplished by
3.4.5 Coolant Inhibitor filling with a pre-mix solution.
The importance of a properly inhibited coolant Caution: Do not overfill cooling system.
cannot be over-emphasized. A coolant which has A pressurized system needs space for heat
insufficient or no inhibitors at all, invites the expansion without overflowing.
formation of rust, scale, sludge and mineral deposits.
These deposits can greatly reduce the cooling 3.4.6.1 Engines without Coolant Recovery Tank
systems efficiency and protection capabilities. (Figure #35A)
Recommended supplemental coolant inhibitors are a Install the pressure cap, start and run engine for
combination of chemical compounds which provide approximately 5 minutes in order to purge the air
corrosion protection, cavitation suppression, pH from the engine cavities.
Page 31 of 51
When verifying that the coolant is at a safe operating
level, it is best to wait until the engine temperature
drops to approximately 120ºF (49ºC), or lower,
before removing the pressure cap.
Figure #35A
Page 32 of 51
Note: Use a fill rate of no more than 10 liters/min (3 have a radiator cooled Clarke engine, you can
gpm). Replace heat exchanger pressure cap. disregard this section. Heat exchanger cooled diesel
engine drivers require a clean source of pressurized
Cap water from the discharge side of the fire pump in
order to keep the engine from overheating by
providing a specified minimum amount of raw water
flow.
Heat Exchanger
Coolant
Figure #35D shows the standard NFPA 20 cooling
Recovery Tank loop piping arrangement. The cooling loop consists
of an Automatic flow line with a 12V or 24V
Figure #35B
solenoid valve (HSC and ES pump applications only)
that is energized to open anytime the engine is called
Remove cap from coolant recovery tank and fill the
upon to run from either the fire pump controller or
coolant recovery tank with a 50/50 coolant mixture to
from the engine instrument panel.
a level of 100mm (4”) from bottom of the tank.
Replace cap.
NOTE: VT type pumps applications do not require a
solenoid valve in the Automatic flow line.
NOTE: With the Mechanical Engine and Alarm
Control Board, See section 3.5.5, the solenoid valve
will open 15 seconds after engine shutdown and will
stay open for 60 seconds. This allows for raw water
to flow through the heat exchanger and reduce the
heat soak rise caused in the engine.
Figure #35C
The second flow line is called the Manual by-pass
Start and run engine with fire pump in a no flow or line and it can be opened at any time if for any reason
low flow condition. Run engine for approximately 1 the engine shows signs of overheating. Each line has
minute. Carefully remove heat exchanger pressure two (quarter turn) shutoff values installed and the
cap while engine is running. normal position of the shutoff valve is to remain open
in the Automatic flow line and remain closed in the
Note: Caution should always be taken when Manual by-pass flow line.
removing a cap from a system under pressure.
NOTE: Opening up both lines to flow is never a
Refill cooling system to the pressure cap sealing problem should there be some concern of engine
surface. Replace heat exchanger pressure cap. overheat, especially if there is an emergency
situation. The Manual by-pass line can only be
Complete deaeration will take several warm up/ cool opened by an operator in the pump room.
down cycles. Always check appropriate coolant level
in coolant recovery bottle. The shutoff valves are all identified to show which
are Normally Open (Automatic flow line) and which
are Normally Closed (Manual by-pass flow line).
3.4.7 Providing adequate Raw Water Supply to the The shutoff valves are also used to isolate water
Engine Heat Exchanger pressure in the event of maintenance to pressure
regulators, strainers and solenoid valve.
3.4.7.1 Raw Water Supply In each flow line there is also a pressure regulator.
Each pressure regulator protects the downstream
Most Clarke diesel engine fire pump drivers are heat piping from over-pressurization which includes the
exchanger cooled and some engines also have a tube side of the engine shell & tube heat exchanger
charge air cooler (CAC) that uses raw water to cool (or CAC) and to control raw water flow rate.
the air before entering the intake manifold. If you Typically the pressure regulators are set to limit
Page 33 of 51
downstream pressure to 60 psi (4 bar). There is a
pressure gauge installed just upstream of the engine
heat exchanger (or CAC) and downstream of the each
pressure regulator. Under normal engine operating
conditions with adequate cooling water flowing thru
the heat exchanger (or CAC) this gauge should
typically read below 20 psi (1.4 Bar).
Figure #35D
3.4.7.3 Setting Raw Water Flow Rate provides basic operating conditions of the engine and
most values are given based upon engine speed. You
The proper amount of raw water flow thru this line is will find this datasheet in the Technical Catalog that
of the utmost importance, and the pressure gauge is shipped with the engine for your specific Clarke
value does little to indicate if there is sufficient flow. model. This datasheet must be available during
When the engine is exercised weekly, the amount of commissioning in order to set the proper minimum
raw water flow exiting the piping to a floor drain raw water flow. You will need to measure the raw
should always be checked to verify it does not appear water temperature and then find the value for
to have diminished. recommended minimum raw water flow at your
measured raw water temperature on the I&O
During initial commissioning of the engine, it is Datasheet and then; with the fire pump flowing 150%
important to correctly set the raw flow rate going thru
the cooling loop. Each Clarke engine model has an
Installation and Operation (I&O) Datasheet that
Page 34 of 51
of rated flow, and the Automatic flow line open; set indicator is showing water flow, the temperature rise
minimum flow by using the adjusting screw at the top is not excessive (usually no more than 40F (4.5C)
of the pressure regulator. over ambient raw water temperature) and the engine
is showing no signs of overheating.
NOTE: To increase flow turn the adjusting screw
clockwise and to reduce flow turn the adjusting screw 3.4.7.5 Raw Water Quality, Strainers and
counterclockwise. Deterioration of Heat Exchanger (or CAC)
You will need to capture the flow for a specific Over time, as the heat exchanger (or CAC) begins to
amount of time coming out of the heat exchanger and plug and foul, this pressure will rise and the flow will
going to a floor drain in order to establish a diminish which could mean that the heat exchanger
reasonably accurate flow rate value. Using a (or CAC) may have to be replaced.
container or bucket of known volume, record the time It can be not stressed enough how important it is to
required to fill the container and compare to the gpm keep these strainers clean: Most engine failures
or L/min value provided on the I&O datasheet. occur due to plugged cooling loop strainers! If the
THIS IS CRITICAL FOR PROPER ENGINE raw water supply has debris in it (leaves, stones, etc)
COOLING AT MAXIMUM PUMP LOAD! After as the strainer accumulates more debris (that will not
setting the pressure regulator in the Automatic pass thru it), the flowrate will continue to diminish
flowline, open the Manual by-pass line valves, and which will eventually starve the engine of adequate
then close the Automatic flowline valves and repeat cooling water flow which will lead to engine
the above process in order to set the flowrate going overheat and catastrophic engine failure. When this
thru the pressure regulator in the Manual by-pass occurs you have no fire protection! Clarke
line. Once this is completed; close the Manual by- recommends that after the initial engine
pass valves and open the Automatic flowline valves commissioning and also prior to each weekly
to restore conditions back to normal. exercise of the engine / fire pump set, both strainers
be removed and cleaned and then re-installed before
starting the engine.
1) A visual flow indicator and temperature Certain local codes may not allow you to discharge
indicator are installed in the discharge (waste the waste water outlet from the engine heat
outlet) piping. exchanger either due to its temperature or it now
2) When waste outlet piping is longer than 15ft being considered hazardous waste. It is
(4.6m) and / or the outlet discharges are more recommended you always check local codes
than 4ft (1.2M) higher than the heat regarding waste water discharge.
exchanger, the pipe size increased by at least
one size.
3) Verify that when the correct flow rate is 3.4.8 Flow Paths of Engine Cooling System
achieved that the inlet pressure to the heat
exchanger (or CAC) does not exceed 60psi The engine coolant flows through the shell side of the
(4bar) heat exchanger (or radiator), engine coolant pump, oil
cooler, engine block and cylinder head, jacket water
If you have such an installation, it is recommended heater, thermostat, expansion tank, and coolant
that you run the engine for a period of time at recovery tank (if equipped).
firepump 150% flow and confirm the visual flow
Page 35 of 51
On heat exchanger equipped engines raw cooling
water flows through the tube side of the charge air Refer to Figures #35E for heat exchanger cooled
cooler, if equipped, and the tube side of the heat engines and #35F for radiator cooled engines for
exchanger. cooling system flow path diagrams.
Figure 35E
Figure 35F
Page 36 of 51
3.5 ELECTRICAL SYSTEM ETR = Energized to Run
LPCB
U071056 Engine
ETS Gauge Panel
See
UL/FM Technical
A
ETR C071612 Front Catalog Figure #37
Opening C13965
Insturment (Mechanical To adjust Belt Tension:
Panel Engines) Check belt tension:
- Give at arrow must be .4” - .6” (10-15mm).
UL/FM See To increase tension of the water pump driving belts:
Front Technical - Loosen alternator or belt tensioner mounting
Opening Catalog bolts A and B.
ETR/ETS C071590 Instrument C13965 - Adjust to proper belt tension.
Panel with (Mechanical - Tighten mounting bolts A and B.
C071571 Engines)
speed switch
Page 37 of 51
3.5.3 Speed Switch (when supplied) and then back it out 1/2 turn. Tighten jam nut while
holding the pickup in position. Reconnect to wiring
In the event of an engine overspeed, the speed switch harness.
signals the main pump controller and also affects an
engine shutdown. A visual overspeed warning lamp 3.5.5 Mechanical Engine Control and Alarm Board
will illuminate on the Clarke panel (figure #37A). (MECAB) Speed Switch Troubleshooting
The OVERSPEED RESET (figure# 9) switch is
included on the instrument panel. Should an This engine may be equipped with a speed switch p/n
overspeed condition occur, investigate the cause and C071571 capable of sensing engine sensor
make necessary corrections before placing engine malfunctions and/or electrical over-current(s) on
back in service. The OVERSPEED RESET must be engine alarm circuits and alerting the user via
manually lifted to reset. flashing status lamps. This flashing status indication
NOTE: This reset operation must be is done so with the red “OVERSPEED
completed to allow a restart. If not, the SHUTDOWN” lamp on the outside of the Clarke
engine will not start thru the main pump instrument panel (Figure #37A) and a red LED
controller or manually. located on the middle of the speed switch inside of
the Clarke instrument panel (Figure #37B). In
OVERSPEED VERIFICATION addition to these flashing status lamps, a “Low
Engine Coolant Temperature Alarm” is sent via
Hold the OVERSPEED VERIFICATION switch in engine / fire pump controller inter-connect circuit
the “up” position. This will provide the main pump #312 as a means to alert the user outside of the
controller with an overspeed signal and engine engine room.
shutdown at 67% of the set overspeed RPM.
Start the engine via the main pump controller; the
speed switch will generate an overspeed signal and
shutdown protecting both the engine and pump.
EXAMPLE
Rated Speed: 1760 RPM
Overspeed Shutdown: 2112 RPM (120% of
1760 RPM)
Verification Shutdown: 1410 RPM (67% of
2112 RPM)
Page 38 of 51
Two (2) blinks – Electrical Current Exceeds 10
Amps on Alarm Circuits: Status lamps will flash Cause:
two times continuously on the Clarke instrument
panel and a “Low Engine Coolant Temperature” Engine coolant temperature sensor circuit is open or
alarm will be sent to the fire pump controller via closed
circuit #312.
Electrical current exceeds 10 amps on one or more Verify wiring and connector plug at engine coolant
engine / fire pump controller inter-connect circuits temperature sensor are secure. Sensor is located
behind engine thermostat housing
Engine run alarm (#2)
Engine overspeed alarm (#3) On the Clarke instrument panel, operate the
Engine low oil pressure alarm (#4) “OVERSPEED RESET” switch for two (2) seconds
Engine high coolant temperature alarm (#5) and release. (Refer to Figure #37C).
Engine low coolant temperature alarm (#312)
“OVERSPEED SHUTDOWN” lamp will flash a
Corrective actions: sequence of one (1) blink, then four (4) blinks. This
is normal. The continuous three (3) blink flash
Check each of the above circuits to determine which
contains the current overload. sequence should turn off at this point.
Cause:
Oil pressure switch failure or magnetic pick-up
failure.
Corrective Actions:
Page 39 of 51
After new switch is replaced: On the Clarke With the engine running, set the High Engine Coolant
instrument panel, operate the “OVERSPEED Temperature DIP switch to “ON” (see Figure #37D).
RESET” switch for two (2) seconds and release. Use a fine pick or small screwdriver and slide the
(Refer to Figure #37C) white slider to the left. Wait for 30 seconds and
controller alarm will activate. Set white DIP switch
“OVERSPEED SHUTDOWN” lamp will flash a slider to “OFF” (right) when simulation is complete.
sequence of one (1) blink, then four (4) blinks. This
is normal. The continuous five (5) blink flash • Alarm 4: Low Engine Coolant Temperature: With
sequence should turn off at this point. the engine not running, set the Low Engine Coolant
Temperature DIP switch to “ON” (see Figure #37D).
If circuit is closed, the oil pressure switch is not Use a fine pick or small screwdriver and slide the
damaged and is working normally as expected. white slider to the right. Controller alarm will
Proceed to engine speed sensor check, below. activate immediately. Set white DIP switch slider to
Engine speed sensor (magnetic pick-up) check “OFF” (left) when simulation is complete.
Verify wiring and connector at engine speed sensor
are secure. Magnetic pick-up is located on top of the Low Coolant Temperature
flywheel housing. Simulation switch
OFF ON
With engine running, verify that the tachometer is
functioning normally. ON OFF
Field simulation of (5) pump controller alarms ETS Governor Solenoid: Use manual stop
override to prevent the engine from starting
• Alarm 1: Over speed Shutdown: Follow during the cycle-crank testing. Override must be
over speed verification steps per section 3.5.3. held continuously each time the engine attempts
a crank start. This will allow the engine to crank
• Alarm 2: Low Oil Pressure: With the engine only but will prevent it from running.
running, jumper across two outer terminals with
wires attached to the engine mounted Low Oil
Pressure switch.
Page 40 of 51
3.6 ENGINE SPEED ADJUSTMENT
4.1 ROUTINE MAINTENANCE
A mechanical governor controls the engine speed. NOTE: The following Routine Maintenance schedule
The governor is built into the fuel injection pump. All is based on an engine usage rate not exceeding 2
governors are adjusted to the rated speed at hours per month. For UL/FM engine models, also
nameplate power or maximum allowed pump load refer to NFPA25.
before leaving Clarke. During Start-Up Inspection or LEGEND:
when placing reconditioned units into service, some Check
minor speed adjustment may be required. It is Clean
recommended that this adjustment be performed by Replace
the authorized Service Dealer representative. o Lubricate
WEEKLY
To adjust the speed of the engine: Air Cleaner
Battery
A. Start the engine by following the “To Start Coolant Hoses
Engine” Procedure in this manual. Coolant Levels
B. Let the engine warm-up. Loosen the jam Cooling Water Solenoid Valve
nut(s) (Figure #38). Exhaust System
C. While observing the instrument panel tach Fuel Tank
rotate the long adjustor clockwise to lower General Inspection
the RPM and counter clockwise to raise the Governor Run-Stop Control
RPM’s until desired speed is obtained. Ref. Jacket Water Heater
Figure #38A. Lubrication Oil Level
D. Holding secure the long adjustor with a Operating Gauges
wrench tighten the jam nut. Remove Water from Fuel Filter
E. Stop engine by following “To Stop Engine” Run Engine
Procedure in this manual. Warning Light
Radiator Core Debris
EVERY 6 MONTHS
Batteries
Battery Charging Alternator
Belts
Cooling Water Strainers
Driveshaft U-Joints
Fuel Lines
EVERY 1 YEAR
Air Cleaner
Coolant Inhibitor
Crankcase Vent System
Figure #38A
o Driveshaft U-Joints
If the engine has been designed and tested for range Fuel & Oil Filters
Heat Exchanger Electrode
rating, stamp the metal tag titled “FIELD SETTING”
with the final adjusted speed, horsepower, and Lubricating Oil
Mounting Isolators
overspeed shutdown setting and keep with the
Wiring System
engine. Refer to Figure #38B.
EVERY 2 YEARS
Air Cleaner
Batteries
Belts
Coolant Hoses
Coolant
Figure #38B Thermostat
4.0 MAINTENANCE SCHEDULE
Page 41 of 51
IMPORTANT: Set main pump controller to “OFF”
while servicing engine. Before turning the main 7.0 OWNER ASSISTANCE
pump controller to the "OFF" position, check with
the maintenance and security supervisors to verify Consult Clarke Service Dealer or Factory. Service
that all the departments concerned will be alerted of Dealers can be located by going to our website:
the temporary interruption of their fire protection www.clarkefire.com.
equipment for normal maintenance or testing. Also,
alert the local fire department in the event that the 8.0 WARRANTY
main pump controller is connected by silent alarm to
headquarters. When servicing is complete, return 8.1 GENERAL WARRANTY STATEMENT
main pump controller selector to "Automatic"
position and the mode selector on the engine to The satisfactory performance of Clarke engines and
“Automatic” position. Advise the appropriate the goodwill of owners / operators of Clarke engines
personnel the engine has been returned to the are of primary concern to the Engine Manufacturer,
“Automatic”. the Engine Service Dealer and Clarke. All provide
support of these products after final installation of the
5.0 TROUBLE SHOOTING complete fire pump and sprinkler system.
Consult Clarke Service Dealer or Factory. Service Warranty responsibility involves both Clarke and the
dealers can be located by going to our website: John Deere service organizations worldwide.
www.clarkefire.com.
The Engine Manufacturer (John Deere) provides
6.0 PARTS INFORMATION Warranty for the basic engine components and Clarke
provides warranty on the accessories added to meet
6.1 SPARE PARTS the NFPA-20 specifications and FM/UL certification
requirements.
To ensure best operation and efficiency of all engine
components, always use genuine Clarke spare parts. 8.2 CLARKE WARRANTY
Orders should specify: All Clarke warranted components have warranty for a
Engine Model Number - See Engine General duration of 24 months beginning at the Start-up date
Engine Serial Number - Specification of the fire pump system. The warranty coverage
Part Number(s) Refer to Engine Maintenance includes replacement of the part and reasonable cost
Parts List section 6.2 or Parts Illustration in of labor for installation. Components failed due to
Technical Bulletin in C13886. improper engine installation, transportation damage,
Contact numbers for spare parts: or misuse is not covered under this warranty.
• www.clarkefire.com For additional warranty details, see the specific
• Phone USA: (513) 771-2200 Ext. 427 (calling warranty statement “John Deere New Engine
within USA) Warranty” on the following page. Also contact
• Phone UK: (44) 1236 429946 (calling outside USA) Clarke direct if you have any questions or require
• Fax USA: (513) 771-5375 (calling within USA) additional information.
• Fax UK: (44) 1236 427274 (calling outside USA)
• E-Mail USA: parts@clarkefire.com Clarke is not responsible for incidental or
• E-Mail UK: dmurray@clarkefire.com consequential costs, damage or expenses which the
owner may incur as a result of a malfunction or
6.2 ENGINE MAINTENANCE PARTS LIST failure covered by this warranty.
Refer to Appendix “A“ at the end of this manual. 8.3 JOHN DEERE WARRANTY
ENGINE MODEL Air Filter Air Filter Oil 8.3.1 Warranty Duration
Service Kit
All 99-55050 C121157 Unless otherwise provided in writing, John Deere*
Figure #39 makes the following warranty to the first retail
Page 42 of 51
purchaser and each subsequent purchaser (if purchase Protection Agency (EPA) and/or California Air
is made prior to expiration of applicable warranty) of Resources Board (CARB); and used in the United
each John Deere new off-highway engine marketed States in equipment. The presence of an emissions
as part of a product manufactured by a company label like the one shown signifies that the engine has
other than John Deere or its affiliates: been certified with the EPA and/or CARB. The EPA
• 12 months, unlimited hours of use, or and CARB warranties only apply to new engines
• 24 months and prior to the accumulation of 2000 having the certification label affixed to the engine
hours of use; and on each John Deere engine used in and sold as stated above in the geographic areas
an off-highway repower application: governed by the regulation agencies.
•12 months, unlimited hours of use.
Note: In the absence of a functional hourmeter,
hours of use will be determined on the basis of 12
hours of use per calendar day. (*John Deere” means
Deere Power Systems Group with respect to users in
the United States, John Deere Limited with respect to
users in Canada, and Deere & Company or its
subsidiary responsible for marketing John Deere
equipment in other counties where the user is
located)
The emissions warranty described below applies only Warranties stated in this manual refer only to
to those engines marketed by John Deere that have emissions-related parts and components of your
been certified by the United States Environmental
Page 43 of 51
engine. For complete engine warranty, less PCV system o Oil filler cap
emissions related parts and components, ref to 8.3.1. o PCV solenoid
o PCV valve
o Crankcase ventilation filter
COVERED EMISSIONS SYSTEMS AND o Crankcase ventilation valve
COMPONENTS Miscellaneous items o Electronic control sensors
System Sample Sub-Systems and Components used in the above o Electronic control units (ECUs)
Air induction system o Air filter housing systems o ECU software
o Air mass sensor assembly o Pump/valve controllers
o Controlled hot air intake system o Wiring harness
o Heat riser o Coolant temperature sensor
o Intake manifold o Emissions labels
o Intercooler o Sealing gaskets
o Turbocharger o Thermocouples
o Wastegate control assembly valve o Thermostats
o Vacuum-sensitive valve/switches
Fuel metering o Aneroid
system (fuel system) o Carburetor 8.3.4 Obtaining Warranty Service
o Choke mechanism
o Electronic injection unit
o Fuel injection assembly Warranty service must be requested of the nearest
o Fuel injection nozzle assembly authorized John Deere engine service outlet before
o Fuel injection injector the expiration of the warranty. An authorized service
o Fuel injector nozzle outlet is a John Deere engine distributor, a John
o Fuel injection valve assembly
o Fuel line Deere engine service dealer, or a John Deere
o Gas pressure regulator equipment dealer selling and servicing equipment
o Pressure relief valve/assembly with an engine of the type covered by this warranty.
o Air restriction sensor Authorized service outlets will use only new or
o Air temperature sensor
o Coolant temperature sensor
remanufactured parts or components furnished or
o Fuel temperature sensor approved by John Deere.
o Mass flow module sensor Authorized service locations and the name of the
o UEGO sensor John Deere division or subsidiary making this
o Throttle warranty are listed in the Parts and Service Directory
Ignition control o Distributor assembly for John Deere Engines.
system o Engine control module At the time of requesting warranty service, the
o Glow plugs purchaser must be prepared to present evidence of the
o Ignition coil date of delivery of the engine.
o Ignition control module
o Ignition sensor
o Ignition wires John Deere reimburses authorized service outlets for
o Spark plugs limited travel expenses incurred in making warranty
EGR system o EGR cooler service repairs in non-John Deere applications when
o EGR valve body travel is actually per formed. The limit, as of the date
Advanced Oxides of o Lean NOx catalysts
Nitrogen (NOx o Nox absorbers
of publication of this statement, is US $300.00 or
controls) o Reductant (urea/fuel) equivalent. If distances and travel times are greater
containers/dispensing systems than reimbursed by John Deere, the service outlet
Catalyst or thermal o Catalytic converter may charge the purchaser for the difference.
reactor system o Double wall portion of exhaust
system
o Exhaust manifold
8.3.5 Warranty Exclusions
o Exhaust gas recirculation valve
Particulate Controls o Control device enclosure and John Deere’s obligations shall not apply to fuel
manifolding injection pump and nozzles during the pump and
o Regenerators nozzle manufacturer’s warranty period on the pump
o Oxidizers
o Traps and nozzles, components and accessories which are
o Filters not furnished or installed by John Deere, nor to
o Precipitators failures caused by such items. When the pump
o Manifold absolute pressure (MAP) manufacturer’s warranty is less than the engine
sensor
warranty, John Deere will reimburse pump repair
Page 44 of 51
costs for warrantable-type failures during the operation and maintenance instructions supplied with
remainder of the original engine warranty period, the engine are followed.
when so documented by the pump manufacturer’s
approved service outlet. Costs of interpreting or translating services.
The cost of normal maintenance and depreciation. Where permitted by law, neither John Deere nor any
company affiliated with it makes any guaranties,
Consequences of negligence, misuse, or accident warranties, conditions, representations or promises,
involving the engine, or improper application, express or implied, oral or written, as to the
installation, or storage of the engine, or improper nonoccurrence of any defect or the quality or
application, installation, or storage of the engine. performance of its engines other than those set forth
herein, and DOES NOT MAKE ANY IMPLIED
Consequences of service performed by someone WARRANTY OR CONDITIONS OF
other than a party authorized to perform warranty MERCHANTABILITY OR FITNESS otherwise
service, if such service, in John Deere’s judgment, provided for in the Uniform Commercial Code or
has adversely affected the performance or reliability required by any Sale of Goods Act or any other
of the engine. statute. This exclusion includes fundamental terms.
Consequences of any modification or alteration of the In no event will a John Deere engine distributor or
engine not approved by John Deere, including, but engine service dealer, John Deere equipment dealer,
not limited to, tampering with fuel and air delivery or John Deere or any company affiliated with John
systems. Deere be liable for incidental or consequential
The effects of cooling system neglect as manifested damages or injuries including, but not limited to, loss
in cylinder liner or block cavitation (“pitting”, of profits, loss of crops, rental of substitute
“erosion”, “electrolysis”). equipment or other commercial loss, damage to the
Any premium for overtime labor requested by the equipment in which the engine is installed or for
purchaser. damage suffered by purchaser as a result of
Costs of transporting the engine or the equipment in fundamental breaches of contract or breach of
which it is installed to and from the location at which fundamental terms, unless such damages or injuries
the warranty service is performed, if such costs are in are caused by the gross negligence or intentional acts
excess of the maximum amount payable to the of the foregoing parties.
service location were the warranty service performed
at the engine’s location.
Page 45 of 51
installed makes any guaranty or warranty of its own emergency fire pump engines supplied by
on any engine warranted by John Deere unless it Clarke.
delivers to the purchaser a separate written guaranty
3. CARB’s determination is not binding on the
certificate specifically guaranteeing the engine, in
local air districts, which have primary
which case John Deere shall have no obligation to the
jurisdiction for implementing and enforcing
purchaser. Neither original equipment manufacturers,
the ATCM. Actual test data in the field or
engine or equipment distributors, engine or
other information established by the local air
equipment dealers, nor any other person or entity, has
districts or CARB that show actual emissions
any authority to make any representation or promise
from an engine supplied by Clarke in excess
on behalf of John Deere or to modify the terms or
of the ATCM limitations could indicate a
limitations of this warranty in any way.
violation of the ATCM and subject the seller,
owner and operator of the engine to penalties
8.3.10 Additional Information
under California law. Although Clarke
believes that the engines supplied by Clarke
For additional information concerning the John Deere
comply with the ATCM based on the
New Off-Highway Engine Warranty, see booklet
available data and methodology accepted by
Engine Owner’s Warranty – Worldwide.
CARB, for the foregoing reasons, Clarke
cannot, and does not, guarantee that its
9.0 ATCM CALIFORNIA EMISSIONS
engines will comply with the ATCM
REGULATIONS FOR STATIONARY ENGINES
emission regulations.
NOTICE AND DISCLAIMER 4. CLARKE MAKES NO WARRANTIES OR
FOR STATIONARY COMPRESSION GUARANTIES, EXPRESS OR IMPLIED,
IGNITION ENGINES INSTALLED IN INCLUDING ANY WARRANTY OF
CALIFORNIA AFTER JANUARY 1, 2005 MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE OR
1. This Notice and Disclaimer is an addendum OTHERWISE, THAT THE ENGINES
to, and made a part of, Clarke’s Fire SUPPLIED BY CLARKE WILL COMPLY
Protection Products, Inc.’s (“Clarke”) WITH THE ATCM. CLARKE ALSO
Standard Terms and Conditions of Sale and, EXPRESSLY DISCLAIMS THAT THE
in all respects not inconsistent therewith, also ENGINES SUPPLIED BY CLARKE WILL,
applies to all sales of stationary compression IN FACT, COMPLY WITH THE ATCM.
ignition engines installed in California after IN NO EVENT SHALL CLARKE BE
January 1, 2005. LIABLE FOR SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES ARISING
2. Stationary diesel-fueled compression ignition
OUT OF OR IN CONNECTION WITH
engines installed in California after January
THESE TERMS AND CONDITIONS OR
1, 2005 are subject to California’s Airborne
THE ENGINES SUPPLIED BY CLARKE
Toxic Control Measure for Stationary
OR FOR INDEMNIFICATION OF BUYER
Compression Ignition Engines (the
ON ACCOUNT OF ANY CLAIM
“ATCM”), Cal. Code Regs. Title 17, Section
ASSERTED AGAINST BUYER, OR FOR
93115. The California Air Resources Board
ANY OTHER DAMAGE OF ANY KIND,
(“CARB”) has reviewed the emissions
WHETHER DIRECT OR INDIRECT, IF
estimation methodology provided by Clarke
THE ENGINES SUPPLIED BY CLARKE
Fire Protection Products, Inc. (“Clarke”) and
DO NOT COMPLY WITH THE ATCM.
has concluded that Clarke has used a valid
methodology for estimating the emissions 5. If Buyer resells any of the goods sold under
from engines supplied by Clarke and that the this Agreement, Buyer shall include
engines presumptively comply with the language in an enforceable agreement with
ATCM’s emissions standards. Clarke’s its buyer that makes the language in this
methodology used existing emissions test Agreement, including Clarke’s disclaimer of
data associated with similar engines to warranties and remedies in paragraph 5,
estimate the emissions produced by the binding on its buyer. Buyer shall defend,
indemnify and hold Clarke harmless from
Page 46 of 51
any claims, causes of action, damages, losses Radiator 12,17,30,41
or expenses (including reasonable attorney’s Water 33
Crankcase Ventilation 27,41
fees) that Clarke incurs by reason of Buyer’s
failure to comply with this paragraph. D
Dipstick, Oil Level 28
6. Each Clarke ATCM Compliant Fire Pump Driveshaft alignment 13
Driver will be affixed with the following Driveshaft Maintenance 17,41
ATCM Tier 2 Label:
E
Electrical System 37
Engine Models 6
Engine Out of Fuel 11
Engine Protective Systems (overspeed) 38
Engine Start-Up Service 16
Exhaust System 26,28
F
Filters:
7. Each Clarke ATCM Compliant Fire Air Cleaner 26,41
Fuel 20,41
Pump Driver will be stamped with new Lubricating Oil 9,29,41
fuel injection pump timing alignment Fuel Specifications 12
marks. Refer to figure #___. Original Fuel System Operation 20
Bleeding 20
‘factory” timing marks will be “X” out. Pump, Injection 5,21,24,41,44
10.0 INSTALLATION & OPERATION DATA Pump, Lift 16
Service 14 to 23
(See Technical Catalog C13965)
G
11.0 WIRING DIAGRAMS Governor Speed Adjustment 41
(See Technical Catalog C13965)
H
Heaters, Engine 12
12.0 PARTS ILLUSTRATION DRAWING
(See Technical Catalog C13965) I
Installation Data *
Installation Instructions 11
13.0 APPENDIX (Alpha Index) L
Lube Oil Recommendations 29
Subject Page Lubricating Oil Volume 30
Lubricating System 28
A
ACTM Compliant Engines 46,47 M
Air Cleaner 26,41 Magnetic Pickup 38
Alternator 37,41 Maintenance Schedule 41
Manual Operation 17
B Model Number Identification 5
Battery Cables 13
Battery Recommendations 13,41 N
Belt Adjustment 37 Name Plate (Engine) 5
C O
Capacities 30 Oil Filter 29
Coolant Recommendations 31 Oil Level Dipstick 28
Cooling System Oil Pressure *
Anti-Freeze Solutions 31 Oil Specifications/Recommendations 29
Cooling System Capacity 30 Operation Data *
Cooling Water Supply (Loop) 17,33 Out Of Fuel Procedures 12
Cooling Water Flow Requirements * Overspeed Reset 38
Filling Procedure 31 Overspeed Verification 38
Heat Exchanger 12,17,33
Inhibitors 30,31,41 P
Maintenance 41,42 Parts Illustrations *
Page 47 of 51
Parts Information 42
Preventive Maintenance Schedule 41
Pump:
Fuel Injection Pump 5,21,24,41,44
Fuel Lift Pump 16
S
Serial Number 5
Shutdown Systems 40
Specifications:
Fuel 12
Lubrication Oil 29
Speed Switch 38
Storage 11
T
Technical Data *
W
Warranty 42
Wiring Diagram:
DC System 32*
AC Heater Systems 32*
Page 48 of 51
Appendix “A”
UF28, 30,
UF10, 12, UF14, 32, 40, 42,
UF34,
20, 22, 24 50, 52, 58,
UF44, 54
AB26 H0, H2, H8 UFAEA0, UFADHG,
Clarke Engine Models UF84
JU4R‐ E8,F2 J8, J2
JU4R‐
JU4R‐09, UF13, JU4R‐
UF53
11, 19, 21 23 UF40, JU4R‐
49, 51 UFAEA9,
E7, F1
Part Description Part Number (standard items only, optional items not shown)
Oil Filter RE59754 RE541420
Fuel Filter (Primary) RE60021 RE522868
Fuel Filter (Secondary) N/A
Air Filter C03249
Alternator C071047 (12V) or C071048 (24V)
Fuel Injection Pump RE509527 RE508613 RE522714 RE522414 RE546674 RE546676
Heat Exchanger C051128 (USA built) or C051001 (UK built)
RIGHT SIDE‐C07888 AND LEFT SIDE‐C07889 or
Starter Motor (12V) RIGHT SIDE C071071 AND LEFT SIDE‐C071072
Starter Motor (24V) RIGHT SIDE‐C071073 AND LEFT SIDE C071074
Switch, Oil Pressure C071273 OR C071884
Switch, Speed C071001 OR C071571
Switch, Coolant Temperature C125678 OR C071881
Turbocharger N/A RE59379 OR RE508898 RE516007 RE532282 RE532290
Thermostat RE64354 C051275 RE64354 C051275 RE64354
Nozzle, Injector C02360 RE531802
Page 49 of 51
JU6H MODELS
UF50,
UFAAQ8,
UF58,
UFKAQ8,
UFD0,
UFAARG,
UFG8, UF52, UF34, UF84,
UF30, UF60, UFKARG,
UFM0, UFD2, UF62 UF54, UFAB76,
UF32 UF68 UFAAPG,
Clarke Engine Models UFM8, UFM2 UFAB54 UFAB84
UFKAPG,
UFABL8,
UFAAS0,
UFABL0,
UFKAS0
UFABL2
Part Description Part Number (standard items only, optional items not shown)
Oil Filter RE59754
Fuel Filter (Primary) RE60021
Fuel Filter (Secondary) N/A
Air Filter C03396
Alternator C071047 (12V) or C071048 (24V)
Fuel Injection Pump RE506084 or RE506083 RE506085 RE522695 RE522415 RE506906
Heat Exchanger C051127 (USA built) or C051002 (UK built)
RIGHT SIDE‐C07888 AND LEFT SIDE‐C07889 or
Starter Motor (12V) RIGHT SIDE C071071 AND LEFT SIDE‐C071072
Starter Motor (24V) RIGHT SIDE‐C071073 AND LEFT SIDE C071074
Switch, Oil Pressure C071273 OR C071884
Switch, Speed C071001
Switch, Coolant Temperature C125678 OR C071881
Turbocharger RE500681 OR RE515738 RE522691 RE508105
Thermostat RE64354 C051275 RE64354
Nozzle, Injector C02360
Page 50 of 51
JW6H MODELS
UFH8, UF50,
Clarke Engine Models UF30, UF38 UF40, UF48
UF58, UF60
Part Description Part Number (standard items only, optional items not shown)
Oil Filter RE57394
Fuel Filter (Primary) AR86745
Fuel Filter (Secondary) RE65431
Air Filter C03244
Alternator C071047 (12V) or C071048 (24V)
Fuel Injection Pump RE501861 RE502806 RE505910
Heat Exchanger C05804
RE69704 or C071072
Starter Motor (12V)
RE43300 or C071074
Starter Motor (24V)
Switch, Oil Pressure C071273 OR C071884
Switch, Speed C071001
Switch, Coolant Temperature C125678 OR C071881
Turbocharger RE502915 RE501987 RE505257
Thermostat AR48675
Nozzle, Injector RE63073 RE515409
Page 51 of 51