Clarke DP6H-UFAA50 Operation And Maintenance Instruction Manual
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Clarke DP6H-UFAA50 Operation And Maintenance Instruction Manual

Clarke DP6H-UFAA50 Operation And Maintenance Instruction Manual

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Operation and Maintenance
Instructions Manual
DP/DQ/DR/DS/DT 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
C133292 rev AF
1/12/22

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Summary of Contents for Clarke DP6H-UFAA50

  • Page 1 Operation and Maintenance Instructions Manual DP/DQ/DR/DS/DT 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.

  • 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 3.3.3 Changing Oil Filter Cartridge 3.3.4 Oil Specification 3.3.5 Oil Capacities 3.4 COOLING SYSTEM 3.4.1 Intended Engine Operating Temperature 3.4.2 Engine Coolant 3.4.3 Water 3.4.4 Coolant Capacities 3.4.5 Coolant Inhibitors 3.4.6 Procedure for Filling Engine 3.4.6.1 Partial Fill 3.4.7 Providing Adequate Raw Water Supply to the Engine Heat Exchanger 3.4.7.1 Raw Water Supply 3.4.7.2 Cooling Loop 3.4.7.3 Setting Raw Water Flow Rate...
  • 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 49...

  • Page 5: Introduction

    MODEL NUMBERING & IDENTIFICATION There are two identification plates attached to each The following paragraphs summarize the “Scope of engine. Clarke Identification Plate: Engine Model, Supply” of the Engine: Serial Number, Rating and Date of Manufacture are shown on this identification plate. The JU Series •...

  • 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 Figure #4 UFKA60 Figure #2 When Clarke furnishes the base (or module) for the engine and pump set, the combined weight of the Figure #3 shows the typical lifting arrangement of a engine and base (or module) will be indicated on the bare engine.
  • Page 8 DECLARATION OF INCORPORATION Tel: +1 (513) 475-3473 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 Take the victim to a ventilated area or into the open air, placing him on his side if he is unconscious. Any user of the Engine who follows the instructions set out in this manual, and complies with the CAUSTIC BURNS instructions on the labels affixed to the engine are working in safe conditions.

  • Page 10: Installation/Operation

    life threatening, move the injured person with Rotating Parts extreme care and then only if strictly necessary. WARNING LABELS Warning labels, in picture form, are applied to the engine. Their meanings are given below. Important Note: Labels that show an exclamation mark indicate that there is a possibility of danger.

  • 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 Never use light-duty or automotive coolants installation, contact should be made with Clarke in the engine that are stated as ASTM-D3306 Customer Support giving exact details of the only.

  • Page 13: Specific Flywheel Coupling Alignment Instructions

    SC2160A 10.9 100-105 contactors. DR8H/R (Metric) (135-142) 13) Note: Clarke Operation and Maintenance (Hi- (See Note #2) Instructions Manual and Clarke parts Tensile) illustration pages are located inside the M16, Class DS0H/R engine gauge panel.
  • Page 14 assembly and torquing of all hardware. This may be B) With the driveshaft in the same orientation as purchased as part number C126758, 50ml bottle. the previous step (Step A), check the Horizontal Angular alignment of the shafts. Note 2 – 4 of the hi-tensile bolts and/or nuts, that are 1.

  • Page 15: Other Coupling Types

    D) With the driveshaft in the same orientation as 2.4.3 Other Coupling Types the previous step (Step C), check the Vertical alignment of the shafts. Consult Factory Clarke website 1. Measure from the mating surface of the www.clarkefire.com additional pump companion hub of the drive shaft information.
  • Page 16 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: Optional Pneumatic Starting System

    IMPORTANT: Main pump controller selector 2.5.1.1 Optional Pneumatic Starting System should be in the OFF position when starting from engine gauge panel. Be sure to return selector on Some engines may be provided with an optional main pump controller and engine gauge panel to pneumatic starting system to crank the engine from a AUTOMATIC after completing manual run.

  • Page 18: To Stop Engine

    2.5.2 To Stop Engine If engine is started from main pump controller use main pump controller to stop the engine. If engine is started from engine gauge panel: Return MODE SELECTOR switch AUTOMATIC/MANUAL STOP position, engine will stop. Close cooling system manual by-pass valve if opened.

  • Page 19: Engine Systems

    Diesel Fuel Specification shall be reconditioned or replaced, the supply tank shall be cleaned internally, and All diesel fire pump drivers manufactured by Clarke the engine fuel filter(s) shall be changed. are designed, tested and warranted for use only with No.

  • Page 20: Bleeding The Fuel System

    A.8.3.4.1.1 Commercial distillate fuel oils Tighten all connections before applying pressure. used in modern diesel engines are subject to Keep hands and body away from pinholes and various detrimental effects from storage. The nozzles, which eject fluids under high pressure. origin of the crude oil, refinement processing Use a piece of cardboard or paper to search for techniques, time of year, and geographical...

  • Page 21: Changing Fuel Filter Cartridge

    Figure #12B – DT2H-UFAA60,98,92,-FMAAX8,X2 models Figure #13D- DT2H models 3.1.3 Changing the Fuel Filter Cartridges Changing the cartridges and bleed any air from the fuel system as per instructions given in section 3.1.1. Fuel filter changes should take place as per recommendations and only use approved filters.

  • Page 22: Fuel Tanks

    Clarke engines are tested in accordance with SAE fitted against the sealing face. • J1349 (Clarke USA) or ISO 3046 (Clarke UK). In And the turn the filter cartridge about ¾ ~ 1 this capacity they may be derated to meet certain site turn more with hands or filter wrench.
  • Page 23 DS0H-UFAA68, DS0H-UFAA60, DS0H-UFAA98, DS0H-UFAA92 DT2H-UFAA20, DT2H-UFAA58, DT2H-UFAA50 DT2H-UFAA88 DT2H-UFAA60, DT2H-UFAA98, DT2H-UFAA92 CAUTION: Do not attempt to remove the air cleaner while an engine is running nor run the engine while the air cleaner is off. Exposed components could cause severe injury to personnel and major internal engine damage could occur should any foreign matter be drawn into the engine.

  • Page 24: Crankcase Ventilation

    Note: Intake Air Shutoff Valve - Engine may include an intake air shutoff valve as an optional 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.

  • Page 25: Exhaust System

    Air filter restriction Base engine (inches of water) DT2H-UFAA20, DT2H-UFAA58, DT2H-UFAA50 DT2H-UFAA88 DT2H-UFAA60, DT2H-UFAA98, Figure #17E DT2H-UFAA92 The installation of the exhaust system should consist of the following: • Personnel protection from hot surfaces. • Adequate supports to prevent strain on the engine exhaust outlet...

  • Page 26: Changing Engine Oil

    3.3.3 Changing Oil Filter Cartridge 1. Turn engine off. 2. Put a tray under the filter to retain spilt lubricating oil. Note: DT2H-UFAA60,98,92,-FMAAX8,X2 (wet exhaust manifold)engines are provided with parallel, duplex oil filters. Each filter is to be replaced by utilizing the duplex valve to cut out that valve.

  • Page 27: Oil Specification

    3.3.4 Oil Specification The following information is provided as a guide for This engine is factory-filled with oil. Clarke Engine users in the selection of a suitable coolant. Important: Do not add makeup oil until the oil level is BELOW the add mark on the dispstick.

  • Page 28: Water

    • IMPORTANT: Provide for adequate heat transfer. • Do not use cooling system sealing additives or Provide protection from cavitation damage. • antifreeze that contains sealing additives. Provide corrosion/erosion-resistant Do not mix ethylene glycol and propylene glycol environment within the cooling system. •...

  • Page 29: Procedure For Filling Engine

    3.4.7.1 Raw Water Supply follow the partial fill instructions below. Most Clarke diesel engine fire pump drivers are heat exchanger cooled and some engines also have a charge air cooler (CAC) that uses raw water to cool the air before entering the intake manifold.

  • Page 30: Cooling Loop

    Clarke engine, you can NOTE: Opening up both lines to flow is never a disregard this section. Heat exchanger cooled diesel problem should there be some concern of engine engine drivers require a clean source of pressurized...

  • Page 31: Setting Raw Water Flow Rate

    Each Clarke engine model has an verify the flowrate going thru the Manual by-pass Installation and Operation (I&O) Datasheet that line.

  • Page 32: Raw Water Quality, Strainers And Deterioration Of Heat Exchanger (Or Cac)

    On DT2H Clarke engines are equipped with an alarm that is engine models the flow also cools the turbocharger meant to signal diminished raw water flow rate and the exhaust manifolds.
  • Page 33 Refer to Figures #35E for DP6H and DQ6H engine models and #35F for DT2H engine models for cooling system flow path diagrams. Figure #26A – DP6H & DQ6H engine models Figure #26B – DR8H, DS0H, DT2H-UFAA40, 58 engine models Page 33 of 49...

  • Page 34: Important Service Notice

    Figure #26C – DT2H-UFAA60,98,92,-FMAAX8,X2 engine models only • 3.4.9 IMPORTANT SERVICE NOTICE Insufficient fluid level • Failure to de-aerate • Any time an engine experiences a high coolant Overheat temperature alarm condition the primary cause of the overheat must be determined and the cause corrected ELECTRICAL SYSTEM to prevent a recurring overheat event..

  • Page 35: Checking Drive Belt Tension And Adjustment

    3.5.2 Checking Drive Belt Tension Check belt tension: - Give at arrow must be 0.4” - 0.6” (10-15mm). Adjustment To increase tension of the water pump driving belts: All drive belts must be adequately tightened to secure - Loosen alternator or belt tensioner mounting that both the engine water pump and battery charging bolts A and B.

  • Page 36: Magnetic Pick-Up

    “OVERSPEED SHUTDOWN” lamp on the outside of Cause: the Clarke instrument panel (Figure #29) and a red LED located on the middle of the speed switch inside Electrical current exceeds 10 amps on one or more of the Clarke instrument panel (Figure #30).
  • Page 37 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 sent to the fire pump controller via circuit #312.

  • Page 38: Field Simulation Of Pump Controller Alarms

    CONTROLLER ALARMS If circuit is open, replace oil pressure switch. Field simulation of (5) pump controller alarms After new switch is replaced: On the Clarke • Alarm 1: Over speed Shutdown: Follow instrument panel, operate the “OVERSPEED over speed verification steps per section 3.5.3.

  • Page 39: Battery Requirements

    • Alarm 2: Low Oil Pressure: DP, DQ, DR, DS: Refer to Clarke drawing (see Page 5) for With the engine running, jumper the engine mounted additional information on Clarke supplied low oil pressure switch at terminal “WK” to batteries.

  • Page 40: Maintenance Schedule

    WEEKLY ❑ Air Cleaner ❑ Battery Belts ❑ Coolant Hoses ❑ Coolant Leaks ❑ ❑ Coolant Levels and Condition ❑ Cooling Loop Valves Position Cooling Water Solenoid Valve ❑ Cooling Water Discharge ❑ Exhaust System ❑ ❑ Fuel Tank Figure #37B – DP6H models ❑...

  • Page 41: Trouble Shooting

    The satisfactory performance of Clarke engines and “Automatic”. the goodwill of owners / operators of Clarke engines are of primary concern to the Engine Manufacturer, 5.0 TROUBLE SHOOTING the Engine Service Dealer and Clarke. All provide support of these products after final installation of the Consult Clarke Service Dealer or Factory.
  • Page 42 SUPPLIER’s liability under this warranty shall This rating should be applied where reliable utility power is available. A Fire Pump rated engine should be IN LIEU OF ALL OTHER LIABILITIES OF be sized for a maximum of 70% average load factor SUPPLIER defect material...
  • Page 43 Any defect and / or functional difficulty of under Warranty. Engines resulting from any incidental, consequential or rated costs such as costs for BUYER shall carry out all repairs and the fitting of traveling transport, communication expenses, all replacement parts covered by the Warranty and extra costs due to the installation in making SUPPLIER will compensate BUYER the net labor the Engines accessible, docking and cranes,...
  • Page 44 furnished and / or installed the new parts to replace BUYER shall be responsible for the proper storage the defective parts (repair date). Warranty claims and maintenance not be decrease the performance of received beyond the forty-five (45) day period will the Engines during the period of time from unloading of Engines by the carrier of Port of Destination until automatically be denied.
  • Page 45 APPENDIX – 1 WARRANTY PERIOD Rating ENGINE COVERAGE * MONTHS MONTHS Engine (from (from Hours Shipping Delivery date) Date) Fire Pump 0 - 24 0 - 18 * WHICHEVER OCCURS FIRST 9.0 INSTALLATION & OPERATION DATA (See Page 5) 10.0 WIRING DIAGRAMS (See Page 5) 11.0 PARTS ILLUSTRATION DRAWING (See Page 5)
  • Page 46 12.0 APPENDIX (Alpha Index) Subject Page Subject Page Installation Data Installation Instructions Air Cleaner 12,22,23,40,43 Alternator 35,40 Lube Oil Recommendations Lubricating Oil Volume Battery Cables 15,16 Lubricating System Battery Recommendations Belt Adjustment Magnetic Pickup Maintenance Schedule Capacities 27,28 Manual Operation 15,16 Coolant Recommendations Model Number Identification...
  • Page 47 Appendix “A” DP6H & DQ6H ENGINE MODELS Clarke Engine Models DP6H DQ6H Part Number (standard items only, optional items not Part Description shown) Oil Filter C04571 C04569 Fuel Filter (Primary) C02736 Fuel Filter (Secondary) Air Filter C03749 C03244 Alternator C072092...
  • Page 48 Appendix “A” (continued) DR8H, DS0H, & DT2H (DRY EXHAUST MANIFOLD) ENGINE MODELS DT2H-UFAA20, DT2H-UFKA20, DT2H-FMAA40, DT2H-FMKA40, DT2H-UFAA58, Clarke Engine Models DR8H DS0H DT2H-UFKA58 DT2H-UFAA50, DT2H-UFKA50, DT2H-UFAA88, DT2H-UFKA88 only Part Description Part Number (standard items only, optional items not shown) Oil Filter C04569 R.
  • Page 49 Appendix “A” (continued) DT2H (WET EXHAUST MANIFOLD) ENGINE MODELS DT2H-UFAA60,98,92,-FMAAX8,X2, Clarke Engine Models UFKA60,98,92 only Part Number (standard items only, optional Part Description items not shown) Oil Filter C04569 (4) Fuel Filter (Primary) C02736 (4) Fuel Filter (Secondary) Air Filter...

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