Clarke C32H Operation And Maintenance Instruction Manual
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Clarke C32H Operation And Maintenance Instruction Manual

Clarke C32H Operation And Maintenance Instruction Manual

Electronic engines for fire pump applications
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Operation and Maintenance
Instructions Manual
C32H MODELS
ELECTRONIC ENGINES
FOR
FIRE PUMP APPLICATIONS
This manual covers Caterpillar Engines
Prepared by Clarke
for fire pump service
Clarke Fire Protection Products, Inc.
Clarke Fire Protection Products, Ltd.
100 Progress Place
Unit 1, Grange Works
Cincinnati, OH 45246
Lomond Road
U.S.A.
Coatbridge
ML5 2NN
United Kingdom
TELE: +1.513.475.3473
TELE: +44(0)1236 429946
FAX: +1.513.771.0726
FAX: +44(0)1236 427274
www.clarkefire.com
C138229
02/23
RevC

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Summary of Contents for Clarke C32H

  • Page 1 C32H MODELS ELECTRONIC ENGINES FIRE PUMP APPLICATIONS This manual covers Caterpillar Engines Prepared by Clarke for fire pump service Clarke Fire Protection Products, Inc. Clarke Fire Protection Products, Ltd. 100 Progress Place Unit 1, Grange Works Cincinnati, OH 45246 Lomond Road U.S.A.

  • Page 2: Table Of Contents

    CONTENTS SUBJECT PAGE 1.0 INTRODUCTION 1.1 IDENTIFICATION/NAMEPLATE 1.2 SAFETY/CAUTION/WARNINGS 1.3 PRECAUTIONS FOR WELDING 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 2.2.3 Coolant System 2.2.4 Removal from Storage 2.3 INSTALLATION INSTRUCTIONS 2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 2.4.1 Driveshaft 2.5 WEEKLY TEST...
  • Page 3 3.2.5 Exhaust System 3.3 LUBRICATION SYSTEM 3.3.1 Checking Sump Oil 3.3.2 Changing Engine Oil 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 3.4.7 Providing Adequate Raw Water Supply to the Engine Heat Exchanger...
  • 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 5: Introduction

    Caterpillar Identification Label: The second identification tag contains the Caterpillar Feature This manual provides all the information necessary to Code and Serial Number. On the C32H Series, the operate your newly acquired engine safely and Caterpillar identification tag is located on the efficiently, and perform routine servicing correctly.

  • 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 (3266) 7200 C32H0-UFAC48 (3266) 7200 C32H0-UFAC50 (3266) 7200 C32H0-UFAC58 (3266) 7200 C32H0-UFAC60 (3266) 7200 C32H0-UFAC68 (3266) 7200 *C32H0-UFAC12-D (3266) 7200 *C32H0-UFAC22-D (3266) 7200 *C32H0-UFAC32-D (3266) 7200 *C32H0-UFAC42-D (3266) 7200 *C32H0-UFAC52-D (3266) 7200 *C32H0-UFAC62-D (3266) Figure #4 * Clarke PLD Model...
  • Page 8 Figure #5...
  • Page 9 WHAT TO DO IN AN EMERGENCY CAUSTIC BURNS Any user of the Engine who follows the instructions set 1) Caustic burns to the skin are caused by acid out in this manual, and complies with the instructions escaping from the batteries: on the labels affixed to the engine are working in safe ...

  • Page 10: Precautions For Welding

    Important Note: Labels that show an exclamation Jacket Water Heater Voltage mark indicate that there is a possibility of danger. Heat Exchanger Maximum Working Pressure Coolant Mixture Air Filter Installation Lifting Point 1.3 PRECAUTIONS FOR WELDING IMPORTANT: ALWAYS disconnect electronic Control Module (ECM) connectors before welding.

  • Page 11: Installation/Operation

    2.2.2 Long-Term Storage the inlet by removing the plug for checking turbocharger boost pressure. The minimum Note: It is recommended that a Clarke Service Dealer application rate for the VCI oil mixture is 5.5 perform the steps outlined in this section.

  • Page 12: Coolant System

    VCI oil and 50 percent engine oil onto the Completely fill the cooling system before storage. (It following components: flywheel, ring gear is common for Clarke to ship the engine pre-filled with teeth and starter pinion. Install the covers in coolant.) order to prevent evaporation of the vapors from the VCI oil.

  • Page 13: Installation Instructions

    Operation Data Sheets. If there is any doubt about an cover or covers. Put a large amount of engine installation, contact should be made with Clarke oil on the camshaft, cam followers, and valve Customer Support giving exact details of the problem.

  • Page 14: Specific Flywheel Coupling Alignment Instructions

    Angular tolerance, the drive shaft must be installed 8) Connect jacket water heater (if supplied) to between the flywheel and the flanged hub on the pump AC power source. For C32H Series, the shaft. electrical supply requirements are indicated on Before beginning the alignment checks and making the connection box.
  • Page 15 The following steps describe the proper way to check TIGHTEN- DRIVE BOLT alignment. A small pocket scale or ruler with MODELS SHAFT SIZE TORQUE millimeter markings is recommended to make all /GRADE ft-lbs measurements. (N-m) C32H0- UFAC10 Before removing the drive shaft guard, disconnect the negative battery cable from both batteries.

  • Page 16: Weekly Test

    measurement must equal measurement at point H + 1 mm. Re-install all guards and grease fittings before reconnecting the battery cables. Figure #7b C) To check the Vertical Parallel Offset, the driveshaft must be re-orientated. ○ 1. Rotate the shaft 90 so the reference “CD”...

  • Page 17: Starting/Stopping The Engine

    C32H models from Clarke are equipped with a “Soft Installation & Operation Data Sheet (see Page 5). Start” feature to allow operation at a reduced speed.

  • Page 18: Describing Engine Gauge Panel

    The 2.6.3.1 ECM Selector Switch and Primary/Alternate engine should then be re-started manually. (See section 2.6.1). Contact a Clarke Authorized Service Dealer immediately when this situation occurs to Clarke UL/FM Engines come equipped with dual troubleshoot. (See section 7.0).

  • Page 19: Dual Ecm Automatic Switching

    SPN 2145 FMI 9 will be displayed on the diagnostic gauge. 2.6.3.3 Programming ECM with Automatic Switching Device This procedure will be performed by Clarke Certified Service Dealer or a Cat Dealer. BASE & green status In the event of a failed or damaged ECM, programming will be required on the replacement unit.

  • Page 20: Using Power View Gauge

    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). 1.
  • Page 21 2. The six items of the “Main Menu” will be Figure #9D displayed. Figure #9E 3. Pressing the “Arrow” (A&B) keys will scroll through the menu selections. Main Menu Navigation NOTE: The display gauge must be powered to User Settings Adjustment navigate the diagnostic gauge screens.
  • Page 22 See below for an example of adjusting the “Language”. 3. The following “Fire Pump Parameters” screen will appear. This screen will not be populated with data unless the engine is a Clarke PLD (Pressure Limiting Driver).
  • Page 23 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”...
  • Page 24 7. Use the “Arrow” (A&B) keys to highlight the 5. On the “User Gauges” screen, use the “Arrow” parameter to add to the “Auxiliary Parameters” (A&B) keys to highlight the gauge to replace. display. Then press the “Enter” (E) key. This Press the “Enter”...
  • Page 25 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. 1. Starting at the six-up display, press the “Menu” (C) key.
  • Page 26 Accessing Stored Trouble Codes 1. Starting at the six-up display, press the “Menu” key. 5. Pressing the “Escape” (D) key will return you to the “Engine Settings” menu. Press the “Arrow” (B) key to highlight “Software Revision”. Then press the” Enter” (E) key. The following screen will appear.
  • Page 27 4. Press the “Arrow” (A&B) keys to highlight “Stored Faults” and press the “Enter” (E) key. Accessing Active Trouble Codes The following screen will appear. For description of trouble codes, see chart in Troubleshooting Section. 1. During normal operation, the default six-up display will be visible.
  • Page 28 IMPORTANT: Ignoring active trouble codes can result in severe engine damage. 5. The screen will return to the six-up display, but the display will contain the warning icon. The yellow LED will also remain illuminated. The 3. If the arrows appear above keys A&B, there warning icon and yellow LED will remain in are more trouble codes that can be viewed by place until the fault condition is corrected.
  • Page 29 Reset”. Once reset, the engine will be ready to Engine Shutdown Codes restart. Note: For Clarke Engine models, the only shutdown 4. The engine will NOT restart and run until the will be due to an overspeed condition. overspeed reset procedure is performed. See Section 3.5.3 for more details about the...

  • Page 30: Engine Systems

    3.1.1 Diesel Fuel Specification be stored for a minimum of one year without degradation beyond that allowed in 8.3.4.1.1 All diesel fire pump drivers manufactured by Clarke are designed, tested and warranted for use only with 8.3.4.3 When provided,...

  • Page 31: Bleeding The Fuel System

    The priming pump is located on the maintenance systems permanently installed on secondary filter base on your Clarke C32H the fuel storage tanks have proven to be engine. See Figure #11. successful at maintaining fuel quality. An...

  • Page 32: Changing Fuel Filters

    3) Remove element (1) from the mounting base while bowl (2) is still attached. 4) Dispose of the filter contents appropriately. On C32H engines, the bowl is a part of the filter element and not removeable. 5) Lubricate the top seal of the element (1) with clean diesel fuel.

  • Page 33: Fuel Tanks

    C32H0-UFAC48 C32H0-UFAC42 Clarke engines are tested in accordance with SAE C32H0-UFAC38 J1349 (Clarke USA) or ISO 3046 (Clarke UK). In this C32H0-UFAC32 capacity, they may be de-rated to meet certain site conditions, failure to do so can seriously impede the...

  • Page 34: Crankcase Ventilation

    Vapors are expelled through a vent pipe attached to the flywheel housing. Ref. Figure #15. C32H0-UFAC12 Contact Clarke for an optional breather kit if vapors accumulate in your pump room. The installation of the exhaust system should consist of the following: ...

  • Page 35: Lubrication System

    Figure #17. 3.3.4 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 36: Engine Coolant

    CAPACITY accelerate corrosion, while hardness (percentage of QUARTS (LITERS) magnesium and calcium salts broadly classified as C32H-All Models 83 (78.5) carbonates) causes deposits of scale. Water within the limits specified in the following table is satisfactory as an engine coolant when properly inhibited. Use of 3.4.5 Coolant Inhibitors...

  • Page 37: Procedure For Filling Engine

    3.4.7.1 Raw Water Supply put in service. This is best accomplished by filling with a pre-mix solution. Refer to Figure #18 for proper Most Clarke diesel engine fire pump drivers are heat fill level. exchanger cooled and some engines also have a charge air cooler (CAC) that uses raw water to cool the air Caution: Do not overfill cooling system.

  • Page 38: Cooling Loop

    UL Listed fire pump driver. the event of maintenance to pressure regulators, Clarke cooling loops are FM Approved to meet strainers and solenoid valve. Shut off valves in the standard sizing conditions of 50% blocked wye...

  • Page 39: Setting Raw Water Flow Rate

    (low raw water important to correctly set the raw flow rate going thru flow). the cooling loop. Each Clarke engine model has an After verifying raw water flow rate in the Automatic Installation and Operation (I&O) Datasheet that...

  • Page 40: Raw Water Outlet

    3.4.7.4 Raw Water Outlet Clarke engines are equipped with an alarm that is meant to signal diminished raw water flow rate NOTE: NFPA 20 does allow for the heat exchanger (terminal 311), possibly due to clogged raw water outlet flow to be returned to a suction reservoir. This strainers in the cooling loop.

  • Page 41: Flow Paths Of Engine Cooling System

    3.4.8 Flow Paths of Engine Cooling System The engine coolant flows through the shell side of the heat exchanger (or radiator), engine coolant pump, oil cooler, turbo chargers, engine block and cylinder head, jacket water heater, thermostat, expansion tank, and coolant recovery tank (if equipped). On heat exchanger equipped engines raw cooling water flows through the tube side of the charge air cooler, if equipped, and the tube side of the heat...

  • Page 42: Important Service Notice

    Figure 21B- radiator cooled engines 3.4.9 IMPORTANT SERVICE NOTICE 3.4.9.1 Water Pump Cavitation Any time an engine experiences a high coolant Cavitation is a condition that occurs when bubbles temperature alarm condition the primary cause of the form in the coolant flow in the low pressure areas of overheat must be determined and the cause corrected the cooling system and implode as they pass to the to prevent a recurring overheat event.

  • Page 43: Electrical System

    Document the engine will be ready to restart. C073148 Instrument Panel C073150 ECM Harness OVERSPEED VERIFICATION C32H-all models C073151 Engine Harness Start the engine via the main pump controller. Hold Description Reference Drawing No. the OVERSPEED VERIFICATION switch in the...

  • Page 44: Battery Requirements

    4.0 MAINTENANCE SCHEDULE 3.5.5 Battery Requirements 4.1 ROUTINE MAINTENANCE All Clarke engine models require 8D batteries, as NOTE: The following Routine Maintenance schedule sized per SAE J537 and NFPA20. The battery is based on an engine usage rate not exceeding 2 should meet the following criteria: hours per month.

  • Page 45: Trouble Shooting

    WEEKLY normal maintenance or testing. Also, alert the local fire department if the main pump controller Air Filter  is connected by silent alarm to headquarters. Battery  When servicing is complete, return main pump Coolant Hoses  controller selector to "Automatic" position and Coolant Levels ...
  • Page 46 FMI 03 yields engine coolant temperature Engine Coolant Temperature Input input voltage too high. Voltage High Always contact your Clarke service dealer for Engine Coolant Temperature Input help in correcting diagnostic trouble codes Voltage Low which are displayed for your engine.

  • Page 47: Parts Information

    Clarke engines correcting these codes: are of primary concern to the Engine Manufacturer, the Engine Service Dealer and Clarke. All provide EE – Error XXXXX – EP support of these products after final installation of the No Data complete fire pump and sprinkler system.

  • Page 48: Keyword Index

    (See www.clarkefire.com) Heater, Engine 9, 13, 36, 40, 42, 44 12.0 KEYWORD INDEX Subject Page Subject Page Air Filter 9, 10, 13, 32, 33, 44, 49 Installation Data Alternator 11, 42, 44, 49 Installation Instructions 10-15 Battery Cables 13, 15, 16 Lubricating Oil Volume Battery Requirements Lubricating System...
  • Page 49 * See www.clarkefire.com Appendix “A” C32H MODELS PARTS MATRIX C32H0-UFAC68 C32H0-UFAC62 C32H0-UFAC60 C32H0-UFAC58 C32H0-UFAC52 C32H0-UFAC50 C32H0-UFAC48 C32H0-UFAC42 C32H0-UFAC40 Clarke Engine Models C32H0-UFAC38 C32H0-UFAC32 C32H0-UFAC30 C32H0-UFAC28 C32H0-UFAC22 C32H0-UFAC20 C32H0-UFAC18 C32H0-UFAC12 C32H0-UFAC10 Part Description Part Number (standard items only, optional items not shown) 1R1808 (Qty.2)
  • Page 50 Appendix “B”...

  • Page 52: Appendix "C" Pld Maintenance And Operation

    15.0 APPENDIX “C” – PLD MAINTENANCE AND OPERATION 15.1 OVERVIEW AND PRINCIPLES OF Note: With most pressure control systems there is OPERATION some pressure overshoot upon start up (see Figure #1). The Pressure Limiting Driver (PLD) incorporates a Speed Control System used to limit the total discharge system pressure by reducing the pump driver speed from the rated speed.
  • Page 53 This appendix to the operator’s manual only Example: pertains to the PLD features of the Clarke Engine. Model: C32H0-UFAD12-D This section should be used in conjunction with  C = Caterpillar base engine prepared by Sections 1 through 14 of the Operations and...
  • Page 54 Suction supply curve (2 points min.) pressures as low as 0 psi absolute. (See Figure Elevation of system resistance curve #25). It will be necessary to run Clarke’s VSSLC Calculator program to determine compatibility with the installation. This can be accessed through Clarke’s website,...
  • Page 55 Figure #25 – System Schematic, Clarke PLD...
  • Page 56 15.2.2 Start-Up Inspection Instructions  NOTE: The purpose of disabling the VSPLC / VSSLC is to allow for testing 15.2.2.1 Disabling VSPLC / VSSLC of the pump with the PLD Speed  To disable the VSPLC / VSSLC, Control System de-activated. This only occurs during initial start-up and disconnect the wiring harness by during the annual pump test.
  • Page 57 15.2.3 Operation and message will be displayed on the Powerview gauge on the engine instrument 15.2.3.1 Freeze Protection panel (See Figure #26). An alarm signal will also be sent to terminal #302 of the fire Protect the unit from freezing. pump controller.
  • Page 58 Figure #28 – Clarke Instrument Panel 1 – Powerview Gauge 2 – Emergency operating instructions 5 – Warning Light 3 – Automatic / Manual Mode Selector Switch 6 – VSPLC / VSSLC wiring harness 4 – Manual Crank Controls 7 – Manual Stop 15.2.3.3 Adjustments...
  • Page 59 Figure #29 – Wiring Diagram...
  • Page 60 15.4 MAINTENANCE 15.4.1 Weekly Exercise – Record pump shutoff pressure and engine RPM. Maintain weekly readings in a log for future reference. 15.5 TROUBLESHOOTING 15.5.1 Powerview Gauge Diagnostics  In the event of the VSPLC or VSSLC pressure transmitter (See Figure #4, Detail “A”) failure, a warning light and message will be displayed on the Powerview on the engine...
  • Page 61 Each engine has a minimum RPM it can operate at. Minimum RPM is based upon several factors, therefore in order to determine if the Clarke PLD equipped engine can “trim” enough pressure for a particular installation, it will be necessary to run Clarke’s “PLD Calculator”...

This manual is also suitable for:

C32h0-ufac10C32h0-ufac18C32h0-ufac20C32h0-ufac28C32h0-ufac30C32h0-ufac38 ... Show all

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