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Operation and Maintenance
Instructions Manual
ZE / ZF MODEL ENGINES
FOR
FIRE PUMP APPLICATIONS
Clarke UK, Ltd.
Clarke Fire Protection Products, Inc.
Unit 1, Grange Works
100 Progress Place
Lomond Road
Cincinnati, OH 45246
Coatbridge
U.S.A.
ML5 2NN
United Kingdom
TELE: +44(0)1236 429946
TELE: +1.513.771.2200 Ext. 427
FAX: +44(0)1236 427274
FAX: +1.513.771.5375
www.clarkefire.com
C136142 revH
11/18
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Table of Contents
Troubleshooting
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Summary of Contents for Clarke ZE
- Page 1 Operation and Maintenance Instructions Manual ZE / ZF MODEL ENGINES FIRE PUMP APPLICATIONS Clarke UK, Ltd. Clarke Fire Protection Products, Inc. Unit 1, Grange Works 100 Progress Place Lomond Road Cincinnati, OH 45246 Coatbridge U.S.A. ML5 2NN United Kingdom TELE: +44(0)1236 429946 TELE: +1.513.771.2200 Ext.
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Page 2: Table Of Contents
CONTENTS SUBJECT PAGE 1.0 INTRODUCTION 1.1 IDENTIFICATION/NAMEPLATE 1.2 SAFETY/CAUTION/WARNINGS 2.0 INSTALLATION/OPERATION 2.1 TYPICAL INSTALLATION 2.2 ENGINE STORAGE 2.2.1 Storage Less than 1 year 2.2.2 Extended Storage Maintenance Procedure 2.3 INSTALLATION INSTRUCTIONS 2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 2.4.1 Listed Driveshaft 2.4.2 Driveshaft 2.4.3 Other Coupling Types 2.5 STARTING/STOPPING THE ENGINE... - Page 3 3.5.6 Field Simulation of Pump Controller Alarms 3.5.7 Battery Requirements 3.6 ENGINE SPEED ADJUSTMENT MAINTENANCE SCHEDULE 4.1 ROUTINE MAINTENANCE TROUBLE SHOOTING PARTS INFORMATION 6.1 SPARES 6.2 ENGINE MAINTENANCE PARTS LIST OWNER ASSISTANCE WARRANTY 8.1 GENERAL WARRANTY STATEMENT 8.2 CLARKE WARRANTY Page 3 of 41...
- Page 4 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 41...
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Page 5: Introduction
Supply” of the Engine: There are two identification plates attached to each The CLARKE Engine supplied has been engine. Clarke Identification Plate: Engine Model, designed for the sole purpose of driving a Serial Number, Rating and Date of Manufacture stationary Emergency Fire Pump. -
Page 6: Safety/Caution/Warnings
Approach with caution. It is the responsibility of the builder of the machine using a Clarke engine to optimize the application in terms of maximum end user safety. - Page 7 (or module) is furnished with lifting holes. Figure #4 When Clarke furnishes the base (or module) for the engine and pump set, the combined weight of the engine and base (or module) will be indicated on unit.
- Page 8 Tel: +1 (513) 475-3473 DECLARATION OF INCORPORATION Fax: +1 (513) 771-0726 Product: Description – Diesel Engines Manufacturer – Clarke Fire Protection Products, USA Model Number – Serial Number – Year of Manufacture - Contract Number – Customer Order Number –...
- Page 9 WHAT TO DO IN AN EMERGENCY lights or activate electric bells or telephones so as to avoid explosions. Any user of the Engine who follows the instructions set out in this manual, and complies with the Take the victim to a ventilated area or into the open instructions on the labels affixed to the engine are air, placing him on his side if he is unconscious.
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Page 10: Installation/Operation
injured person permission from that person must be received until you can help him. Unless the injury is life threatening, move the injured person with extreme care and then only if strictly necessary. WARNING LABELS Warning labels, in picture form, are applied to the Jacket Water Heater Voltage engine. -
Page 11: Engine Storage
ADDITIONAL PRESERVATION SERVICE: To restore the normal operation running conditions of Storing engines requires special attention. Clarke the engine, carry out the following: engines, as prepared for shipment, may be stored for a minimum of one year. During this period, they 1) Fill the engine sump with the normal should be stored indoors in a dry environment. - Page 12 Operation Data Sheets. If there is any doubt about an 3.3 Lubrication System. installation, contact should be made with Clarke 6) Connect fuel supply and return line to fuel Customer Support giving exact details of the supply tank plumbing.
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Page 13: Specific Flywheel Coupling Alignment Instructions
Note 2 – 4 of the hi-tensile bolts and/or nuts, that are 13) Note: Clarke Operation and Maintenance used to connect the driveshaft to the drive disc and Instructions Manual and Clarke parts... - Page 14 Figure #7a Figure #7c B) With the driveshaft in the same orientation as D) With the driveshaft in the same orientation as the previous step (Step A), check the the previous step (Step C), check the Vertical Horizontal Angular alignment of the shafts. 1.
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Page 15: Other Coupling Types
Be sure to return selector on main pump controller and engine gauge panel to 2.4.3 Other Coupling Types AUTOMATIC after completing manual run. Consult Factory Clarke website www.clarkefire.com additional Position MAIN PUMP CONTROLLER information. -
Page 16: Optional Pneumatic Starting System
UL/FM Front Opening Instrument Panel Figure #9 1 – Emergency Operating Instructions 6 – Overspeed Verification 2 – Automatic / Manual Mode Selector 7 – Overspeed Indication Light 3 – Manual Crank Controls 8 – Oil Pressure Gauge 4 – Overspeed Reset 9 –... -
Page 17: To Stop Engine
2.5.2 To Stop Engine IMPORTANT: DO NOT leave the MODE SELECTOR switch in the MANUAL RUN position If engine is started from main pump controller use during AUTOMATIC operation. (The controller main pump controller to stop the engine. will be unable to stop the engine and DAMAGE MAY RESULT). -
Page 18: Weekly Test
3.0 ENGINE SYSTEMS 3.1 FUEL SYSTEM 3.1.1 Diesel Fuel Specification All diesel fire pump drivers manufactured by Clarke are designed, tested and warranted for use only with No. 2-D Diesel Fuel conforming to ASTM International D-975-11b British Standard... -
Page 19: Bleeding The Fuel System
8.3.4.1.1* Fuel degradation testing shall temperature all contribute to the degradation comply with ASTM D975-11b Standard of the fuel as it is handled and stored. These Specification for Diesel Fuel Oils, or ASTM effects begin at the time of fuel refinement D6751 -11b Standard Specification for and continue until consumption. -
Page 20: Changing Fuel Filter Cartridge
Figure #11 Whenever the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. Figure #13A – ZE4H / ZF6H models ZF6H Engine Series: 3.1.3 Changing the Fuel Filter Cartridges 1) Loosen the air bleed valve (A) by hand on fuel filter head. -
Page 21: Fuel Injection Pump Components
NOTE: Do not over oil the reusable element Clarke engines are tested in accordance with SAE J1349 (Clarke USA) or ISO 3046 (Clarke UK). In this capacity they may be derated to meet certain site conditions, failure to do so can seriously impede the performance of the engine and could lead to premature failure. -
Page 22: Crankcase Ventilation
feature that is activated by an overspeed event and provides a positive shutoff of combustion air to the engine. The optional air intake shutoff valve has not been evaluated by UL as part of a UL Listed fire pump driver. 3.2.4 Crankcase Ventilation 3.2.4.1 ZF6H –... -
Page 23: Lubrication System
The installation of the exhaust system should consist ‘FULL” mark on the dipstick with new and of the following: clean lubricating oil of an approved grade. (see Figure 19D) Personnel protection from hot surfaces. Adequate supports to prevent strain on the engine exhaust outlet... -
Page 24: Oil Specification
When the engine has cooled, check the oil The following information is provided as a guide for level on the dipstick and put more oil into the Clarke Engine users in the selection of a suitable sump, if necessary. coolant. -
Page 25: Coolant Capacities
Figure #22 It is imperative that supplemental inhibitors be added 3.4.4 Coolant Capacities to all Clarke engine systems. A pre-charge dosage must be used at the initial fill and the maintenance Ethylene Glycol or Propylene Glycol are acceptable: dosage used at each service interval. Serious damage will occur unless inhibitors are used. -
Page 26: Providing Adequate Raw Water Supply To The Engine Heat Exchanger
The Manual by-pass line can only be opened by an operator in the pump room. Most Clarke diesel engine fire pump drivers are heat The shutoff valves are all identified to show which exchanger cooled and some engines also have a... -
Page 27: Setting Raw Water Flow Rate
Each Clarke engine model has an reasonably accurate flow rate value. Using a Installation and Operation (I&O) Datasheet that... -
Page 28: Raw Water Outlet
Automatic flowline valves Clarke engines are equipped with an alarm that is to restore conditions back to normal. meant to signal diminished raw water flow rate (terminal 311), possibly due to clogged raw water 3.4.7.4 Raw Water Outlet strainers in the cooling loop. -
Page 29: Important Service Notice
On heat exchanger equipped engines raw cooling Refer to Figures #35E for ZF6H engine models for water flows through the tube side of the charge air cooling system flow path diagrams. cooler, if equipped, and the tube side of the heat exchanger. -
Page 30: Checking Drive Belt Tension And Adjustment
3.5.2 Checking Drive Belt Tension bolts A and B. Adjustment - Adjust to proper belt tension. - Tighten mounting bolts A and B. All drive belts must be adequately tightened to secure that both the engine water pump, fuel transfer pump, 3.5.3 Speed Switch (when supplied) and battery charging alternator (when fitted) are operating efficiently. -
Page 31: Mechanical Engine Control And Alarm Board (Mecab) Speed Switch Troubleshooting
“OVERSPEED SHUTDOWN” lamp on the outside of Two (2) blinks – Electrical Current Exceeds 10 the Clarke instrument panel (Figure #29) and a red Amps on Alarm Circuits: Status lamps will flash LED located on the middle of the speed switch inside two times continuously on the Clarke instrument of the Clarke instrument panel (Figure #30). - Page 32 Five (5) blinks on instrument panel – Oil pressure switch or Engine speed sensor (magnetic pick-up) malfunction: Status lamps will flash five times continuously on the Clarke instrument panel and a “Low Engine Coolant Temperature” alarm will be Figure #31 sent to the fire pump controller via circuit #312.
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Page 33: Field Simulation Of Pump Controller Alarms
Once magnetic pick-up is repositioned: On the Clarke instrument panel, operate the “OVERSPEED RESET” switch for two (2) seconds and release. (Refer to Figure #9). The “INITIALIZATION PATTERN” will flash. This Figure #36 is normal. -
Page 34: Battery Requirements
“FIELD SETTING” with the final adjusted speed, horsepower, and 67% All Clarke engine models require 8D batteries, as overspeed verify shutdown setting and keep with the sized per SAE J537 and NFPA20. The battery engine. -
Page 35: Trouble Shooting
Advise appropriate The satisfactory performance of Clarke engines and personnel the engine has been returned to the the goodwill of owners / operators of Clarke engines “Automatic”. are of primary concern to the Engine Manufacturer, Page 35 of 41... -
Page 36: Clarke Warranty
Ratings in this Article show DEUTZ warranty statement “DEUTZ New Engine Warranty” Fire pump engine guidelines on applications. on the following page. Also contact Clarke direct if you have any questions or require additional FIRE PUMP POWER RATING information. - Page 37 WARRANTY PERIOD non-genuine SUPPLIER service parts on non-equivalent in quality and design to genuine SUPPLIER service parts. The warranty period begins both on the shipping date Any defect and / or functional Difficulty of of the Engine and on the first delivery date of the Engines due to the parts replacement with Engine to the customer, whichever date occurs first, non-genuine SUPPLIER service parts on...
- Page 38 follows APPENDIX-2 as attached. to prevent additional damage or corrosion. Warranty compensation may be charged-back, if the removed parts are not properly kept, lost or not returned to APPLICATION OF WARRANTY CLAIMS SUPPLIER as per request. The application of Warranty Claims by BUYER shall If requested by SUPPLIER, the removed parts shall be made in accordance with SUPPLIER’s designated be shipped to SUPPLIER with charges borne by...
- Page 39 Hours date) Date) Fire Pump 0 - 24 0 - 18 * WHICHEVER OCCURS FIRST 9.0 INSTALLATION & OPERATION DATA (See Clarke website) 10.0 WIRING DIAGRAMS (See Clarke website) 11.0 PARTS ILLUSTRATION DRAWING (See Clarke website) Page 39 of 41...
- Page 40 12.0 APPENDIX (Alpha Index) Subject Page Subject Page Installation Data Air Cleaner 21,34,35,38 Installation Instructions Alternator 30,35 Lube Oil Recommendations Battery Cables 14, 15 Lubricating Oil Volume Battery Recommendations 10,14,15,16,18,30,31,34,35 Lubricating System Belt Adjustment 30,35 Magnetic Pickup Capacities 24,25 Maintenance Schedule Coolant Recommendations Manual Operation 15,16,17,24,26,27,28...
- Page 41 Appendix “A” ZE4H / ZF6H ENGINE MODELS ZE4H ZF6H Clarke Engine Models Part Number (standard items only, optional items not shown) Part Description C04691 C04691 Oil Filter C021081 C021081 Fuel Filter (Primary) C021080 C021080 Fuel Filter (Secondary) C03249 C03749 Air Filter...
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