Clarke C18 Operation And Maintenance Instruction Manual
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Clarke C18 Operation And Maintenance Instruction Manual

Clarke C18 Operation And Maintenance Instruction Manual

Engines with nsr or brazed heat-exchanger for constant speed fire pump applications
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Operation and Maintenance
Instructions Manual
C18 MODEL ENGINES
With NSR or Brazed Heat-Exchanger
FOR CONSTANT SPEED FIRE PUMP APPLICATIONS
DOCUMENT ID:
C137833
Rev H
01/23
Clarke UK, Ltd.
Clarke Fire Protection Products Inc.
Unit 1, Grange Works
100 Progress Place
Lomond Road
Coatbridge
Cincinnati, OH
ML5 2NN
45246
United Kingdom
USA
TEL: +44(0)1236 429946
TEL: +1.513.771.2200 Ext. 427
FAX: +44(0)1236 427274
FAX: +1.513.771.5375

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  • Page 1 With NSR or Brazed Heat-Exchanger FOR CONSTANT SPEED FIRE PUMP APPLICATIONS DOCUMENT ID: C137833 Rev H 01/23 Clarke UK, Ltd. Clarke Fire Protection Products Inc. Unit 1, Grange Works 100 Progress Place Lomond Road Coatbridge Cincinnati, OH ML5 2NN 45246...

  • Page 3: Table Of Contents

    Introduction ....................................5 Scope of Supply ..................................5 Identification / Nameplate ..............................5 Safety, Caution and Warnings ............................. 6 Installation ....................................9 Typical Installation ................................. 9 Engine Storage ..................................9 Installation Instructions ..............................11 Specific Flywheel Coupling Alignment Instructions ..................... 12 Operation ....................................
  • Page 4 Engine Maintenance Parts List ............................50 Owner Assistance ................................... 50 Warranty ....................................50 General Warranty Statement ............................50 Clarke Warranty .................................. 50 Caterpillar Warranty ................................51 Installation & Operation Data ............................... 53 Wiring Diagrams ..................................53 Parts Illustration Drawing ............................... 53 Declaration of Incorporation ..............................

  • Page 5: Introduction

    (See Figure #1-1) Caterpillar Identification Label: The second identification tag contains the Caterpillar Feature Code and Serial Number. On the C18 Series, the Caterpillar identification tag is located on the left-hand side of the engine forward of the air intake.

  • Page 6: Safety, Caution And Warnings

    Figure 1-4 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 the unit. Caution, when lifting, lift point should always be over the...
  • Page 7 Declaration of Incorporation CLARKE UK provides the machine manufacturer with a “Declaration of Incorporation” for the Engine, when required, a copy of which is enclosed in the manual. This document clearly states the machine manufacturers’...
  • Page 8 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. Lifting Point Heat Exchanger Maximum Coolant Mixture Working Pressure Rotating Parts Automatic Start...

  • Page 9: Installation

    Engine Storage Coolant System Completely fill the cooling system before storage. (It is common for Clarke to ship the engine pre-filled with coolant.) Clarke Coolant (part # C054129).The only acceptable substitute is COOL-GARD II part number TY26575. Warranty is contingent on utilizing the indicated coolant.
  • Page 10 boost pressure. The minimum application rate for the VCI oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement. Use a sprayer to apply a mixture of 50 percent VCI oil and 50 percent crankcase oil into the exhaust openings. The minimum application rate for the oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement.

  • Page 11: Installation Instructions

    Caterpillar approved fuel conditioners/ additives. For fuel conditioners/additives, check with your local CAT dealer or Clarke. Fuel supply level must meet applicable code requirements. Do not use a copper based or galvanized material for any component of a diesel fuel system. The fuel will chemically react with the zinc resulting in clogged fuel filters and injector systems.

  • Page 12: Specific Flywheel Coupling Alignment Instructions

    Connect negative cables directly to the engine block. Connect each positive cable to the large outer post of the manual starting contactors. Note: Clarke Operation and Maintenance Instructions Manual is located inside the document bag hanging on the side of the engine.
  • Page 13 The following steps describe the proper way to check alignment. A small pocket scale or ruler with millimeter markings is recommended to make all measurements. (Clarke Pocket Scale part number C125781) (Step A) To check the Horizontal Parallel Offset, the driveshaft must be in the proper orientation.
  • Page 14 Verify all driveshaft connecting bolts remain tight. Re-torque per 2.4.2 if necessary. Reinstall top of guard and connect negative battery cables. Other Coupling Types Consult Factory or Clarke website at www.clarkefire.com for additional information.

  • Page 15: Operation

    Operation Starting and Stopping the Engine Before starting the engine for the first time, review section 7.3.5 to ensure there is an adequate Raw Water Supply to the Engine Heat Exchanger. Starting from the Pump Controller On UL/FM engines, use main pump controller for starting and stopping the engine. Should the main pump controller become inoperable, the engine can be manually started and stopped from the engine gauge panel.

  • Page 16: Soft Start

    No provision exists on most electronic engines.C18 models from Clarke are equipped with a “Soft Start” feature to allow operation at a reduced speed. To use the feature, the engine should be started manually from the engine gauge panel. To use the feature: Switch the main fire pump controller to the OFF position.

  • Page 17: Describing Engine Instrument Panel

    ECM Selector Switch and Primary/Alternate ECM Clarke UL/FM Engines come equipped with dual ECMs and an ECM Selector Switch on engine gauge panel. (Item #6). Default position of ECM selector switch is to the Primary ECM. In the event of a failure of the Primary ECM, where-by the engine shuts down or will not start, it will become necessary to manually switch to the Alternate ECM position.
  • Page 18 To program the Alternate ECM: Unplug the BASE dual ECM auto-switching device on the back side of the engine gauge panel door. Insert the service tool, provided in the engine gauge panel, into the connector removed from the BASE. (See Figure #3-5) This will force the panel into Alternate ECM mode.
  • Page 19 Using the PowerView Gauge The PowerView gauge (reference Figure #3-6) allows the operator to view operating conditions and diagnostic trouble codes (DTC’s). Press the menu key (C) to access the various engine functions in sequence. The displays can be selected as either customary English or metric units. The following menu of engine parameters can be displayed on the power view (refer to Figure #9E).
  • Page 20 Figure 3-8 Figure 3-9 User Settings Adjustment From the “Main Menu” screen you can select “User Settings” by highlighting the text and pushing the “Enter” (E) key. The User Settings Screen will appear. This allows user adjustment of Brightness, Contrast, Temperature Units, and Pressure Units Each of these parameters can be adjusted by highlighting the item with use of the “Arrow”...
  • Page 21 ECU via CAN bus protocol. Some of these parameters may not be able to be displayed. Compatibility depends on the specific Clarke engine model you own. To return to the six-up display from the “Auxiliary Parameters” screen, press the “Arrow Right” (E) key once or the “Menu” (C) key twice.
  • Page 22 “Menu” (C) key twice. Engine Settings Data NOTE: The engine settings data is a read only function. All engine settings parameters are pre-set by Clarke. This menu is primarily used for trouble shooting activities. Starting at the six-up display, press the “Menu” (C) key.
  • Page 23 Pressing the “Escape” (D) key will return you to the “Engine Settings” menu. Press the “Arrow” (B) key to highlight “Software Revision”. Press the” Enter” (E) key. The Software Revisions screen will appear. This information may be requested during an attempt to troubleshoot an issue. Press the “Menu”...
  • Page 24 “Faults Menu”. With “Active Faults” highlighted, press the “Enter” (E) key. The first “Active Fault” screen will appear. Engine Shutdown Codes Note: For Clarke Engine models, the only shutdown will be due to an overspeed condition. Figure 3-22...

  • Page 25: Weekly Test

    The six-up display screen will contain the shutdown icon until the trouble code condition is corrected. For Clarke engines, the only shutdown condition is engine overspeed. See Section 8.3 for overspeed reset. The engine will not restart and run until the overspeed reset procedure is performed.

  • Page 26: Fuel System

    Fuel System 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 or British Standard BS2869:2010+A1:2011 Fuels oils for agricultural, domestic and industrial engines and boilers - Specification.

  • Page 27: Bleeding The Fuel System

    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. Priming the C18 Engine when secondary filter has been changed. Open the air purge screw (2) three full turns. Do not remove screw. The air purge screw is located on the secondary filter base.

  • Page 28: Changing The Fuel Filters

    Priming the C18 Engine when the engine has been run out of fuel. Note: Additional steps must be taken to prime the engine when the engine has ceased to run due to an exhausted fuel supply. Fill the fuel tank with clean diesel fuel of the appropriate grade.

  • Page 29: Fuel Tanks

    Figure 4-4 Fuel Tanks Keep the fuel tank filled to reduce condensation to a minimum. Open drain at the bottom of the fuel tank once a week to drain off any possible water and/or sediment. Fill tank after each test run. Note: Per NFPA 25 standards, the fuel tank level must never be less than 67% of its capacity.

  • Page 30: Air/Exhaust System

    Ambient Conditions 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 31: Crankcase Ventilation

    A slight pressure is maintained within the engine crankcase compartment. Vapors are expelled through a vent pipe attached to the rocker cover. Ref. Figure #5-1. Contact Clarke for an optional breather kit if vapors accumulate in your pump room.

  • Page 32: Exhaust System

    Exhaust System Excessive back pressures to the engine exhaust can considerably reduce both engine performance and life. It is therefore important that exhaust systems should be the proper diameter and be as short as possible within the minimum amount of bends. Refer to Installation & Operating Data in Technical Catalog C133941 (see Page 5) for exhaust data.

  • Page 33: Lubrication System

    Oil Specification Diesel Engine Oil This engine is filled at Clarke with SAE 15W-40 oil meeting CAT ECF-3 specification. Important: Do not add makeup oil until the oil level is BELOW the add mark on dipstick. Add Cat DEO 15W-40 or equivalent when makeup oil is required.

  • Page 34: Cooling System

    Intended Engine Operating Temperature The C18 models have an intended engine operating temperature of 190º F (88ºC) to 205º F (96º C). High Coolant Temperature Alarm A high coolant temperature sensor monitors coolant temperature and will set an alarm at 217º F (103º C).
  • Page 35 Raw Water Supply 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. If you have a radiator cooled Clarke engine, you can disregard this section.
  • Page 36 Clarke cooling loops are FM Approved to meet standard sizing conditions of 50% blocked wye strainers, 100degF (38degC) raw water inlet temperature, 80 psi inlet pressure, and 10 psi available at the engine outlet. Figure #7-4 shows the standard NFPA 20 cooling loop piping arrangement. The cooling loop consists of an...
  • Page 37 During initial commissioning of the engine, it is 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 provides basic operating conditions of the engine and most values are given based upon engine speed. You will find this datasheet in the documentation bag that is shipped with the engine for your specific Clarke model.
  • Page 38 Clarke engines are equipped with an alarm that is meant to signal diminished raw water flow rate (terminal 311), possibly due to clogged raw water strainers in the cooling loop. Refer to Figure #7-5 for location of sensors. A circuit board located near the front of the cooling loop monitors differential pressure between the two sensors and will send an alarm to the controller if a low water flow condition exists.
  • Page 39 Certain local codes may not allow you to discharge the waste water outlet from the engine heat exchanger either due to its temperature or it now being considered hazardous waste. It is recommended you always check local codes regarding waste water discharge. NSR Heat Exchanger Maintenance The NSR heat exchanger tube bundle can be removed and cleaned to maintain proper cooling and flow requirements.
  • Page 40 Figure 7-6 Heat Exchanger Cooled Engines Figure 7-7 Radiator Cooled Engines...
  • Page 41 Important Service Notice Any time an engine experiences a high coolant temperature alarm condition the primary cause of the overheat must be determined and the cause corrected to prevent a recurring overheat event.. Additionally, if an event of a restricted flow, collapsed hose, insufficient coolant level or failed pressure cap is experienced, further investigation of the cooling system is required.

  • Page 42: Electrical System

    Instrument Panel (DC Voltage) C072736 ECM Harness (DC Voltage) C072753 C18 [all models] Engine Harness (DC Voltage) C07651 Jacket Water Heater (AC Voltage) Checking Drive Belt Tension and Adjustment All drive belts must be adequately tightened to secure that both the engine water pump and battery charging alternator (when fitted) are operating efficiently.

  • Page 43: Field Simulation Of Pump Controller Alarms

    Warning and Failure Alarms, activate the ECM Failure Reset Switch inside the engine control panel. Battery Requirements All Clarke engine models require 8D batteries, as sized per SAE J537 and NFPA20. The battery should meet the following criteria: Cold Cranking Amps (CCA @ 0°F): 1200 Reserve Capacity (minutes): 430 Refer to Clarke drawing (see Page 5) for additional information on Clarke supplied batteries.

  • Page 44: Maintenance Schedule

    For UL/FM engine models, also refer to NFPA25. The Maintenance Schedule Checklist is an optional document to record Clarke Fire specific maintenance items. Based on NFPA 25 and Clarke Fire maintenance requirements, document C137684 was created for customer and technician record keeping purposes.

  • Page 45: Year Maintenance Items

    Replace the Lubricating Oil. Replace the Coolant. Clarke Coolant (part # C054129).The only acceptable substitute is COOL-GARD II part number TY26575. Warranty is contingent on utilizing the indicated coolant. Check the Mounting Isolators and foundation nuts. (If applicable.) Check the Wiring System connections, tighten if necessary.
  • Page 46 #9-2. Return to Normal Operation Refill the engine coolant Refill the engine coolant using Clarke Fire part number 0C054129 or Cool-Gard II part number TY26575 Turn on the raw water supply Return the manual ball valves on the automatic and bypass side of the cooling loop to the normal position.
  • Page 47 Install the negative battery cable on each engine battery, enable the pump controller battery chargers and return the pump controller to automatic mode. Run the engine During filling of the cooling system, air pockets may form. The system must be purged of air prior to being put in service.

  • Page 48: Troubleshooting

    The FMI identifies the type of failure that has occurred; for example, FMI03 indicates value above normal. Combining the SPN 000110 with FMI 03 yields engine coolant temperature input voltage too high. Always contact your Clarke service dealer for help in correcting diagnostic trouble codes which are displayed for your engine.
  • Page 49 List of Diagnostic Trouble Codes Description Fuel Temperature Input Voltage High Throttle #3 Input High Fuel Temperature Input Voltage Low Throttle #3 Input Low Injector Shorted to Power Source Throttle #2 Input High Injector Wiring Shorted to Ground Throttle #2 Input Low Sensor Supply Voltage High Throttle #1 Input High Sensor Supply Voltage Low...

  • Page 50: Parts Information

    Warranty General Warranty Statement The satisfactory performance of Clarke engines and the goodwill of owners / operators of Clarke engines are of primary concern to the Engine Manufacturer, the Engine Service Dealer and Clarke. All provide support of these products after final installation of the complete fire pump and sprinkler system.

  • Page 51: Caterpillar Warranty

    Caterpillar Warranty...

  • Page 53: Installation & Operation Data

    Installation & Operation Data (See www.clarkefire.com) Wiring Diagrams (See www.clarkefire.com) Parts Illustration Drawing (See www.clarkefire.com)

  • Page 54: Declaration Of Incorporation

    Declaration of Incorporation...
  • Page 55 Appendix A C18H MODELS PARTS MATRIX C18H0-UFAA78 C18H0-UFAD10 C18H0-UFAD50 C18H0-UFAD18 C18H0-UFAC10 C18H0-UFAD58 C18H0-UFAD20 Clarke Engine C18H0-UFAC18 C18H0-UFAD68 C18H0-UFAD28 Models C18H0-UFAC20 C18H0-UFAD70 C18H0-UFAD30 C18H0-UFAC28 C18H0-UFAD78 C18H0-UFAD38 C18H0-UFAD40 C18H0-UFAD48 Part Part Number (standard items only, optional items not shown) Description 1R1808 (Qty.2)

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