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Summary of Contents for Clarke C18
- Page 1 Operation & Maintenance Instructions Manual C18 Model Engines C139519-en Rev A 16 January 2025 Constant and Variable Speed Engines, assembled with TSP-E Instrument Panel and NSR Heat-Exchangers.
- Page 2 Copyright © 2025 Clarke Fire Protection Products, INC. This content is prepared by Clarke Fire Protection Products, INC.
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Page 3: Table Of Contents
Operation & Maintenance Instructions Manual Table of Contents 1. Introduction .......................... 1 1.1. Support Contacts ......................1 1.2. Scope of Supply ......................1 1.3. Identification & Nameplate .................... 1 1.4. Safety, Cautions, and Warnings ..................2 1.5. Basic Rules ....................... 4 2. - Page 4 11.1.3. Parts Illustration Drawing ................. 44 11.2. Owner Assistance ....................44 11.3. Warranty ........................ 44 11.3.1. General Warranty Statement ................44 11.3.2. Clarke Warranty .................... 44 11.3.3. Caterpillar Warranty ..................45 11.4. Installation & Operations Data ..................46 11.5. Wiring Diagram ......................46...
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Page 5: Introduction
1.3. Identification & Nameplate Throughout this manual, the terms “Engine” and “Machine” are used. The term “Engine” refers solely to the diesel engine driver as supplied by CLARKE. The term “Machine” refers to any piece of equipment with which the engine might interface. -
Page 6: Safety, Cautions, And Warnings
The nameplate also contains a QR code that can be scanned with a smartphone barcode reader app. The QR code links to a Clarke webpage specific to the engine serial number where engine specific data can be verified against the nameplate. This information will safeguard against counterfeiting and provide assurance to the authenticity of the Clarke engine. - Page 7 Operation & Maintenance Instructions Manual • FIRE. Put out the fire using extinguishers recommended by the manufacturer of the machine or the installation. • BURNS. Put out the flames on the clothing of the burns victim by means of drenching with water, use of powder extinguisher, making sure not to direct the jets onto the face, blankets or rolling the victim on the ground Do not pull off strips of clothing that are sticking to the skin.
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Page 8: Basic Rules
4100 (1860) 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 equipment Center of Gravity. -
Page 9: Installation
Any such conditions found must be corrected immediately. Completely fill the cooling system before storage. (It is common for Clarke to ship the engine pre-filled with coolant.) Use Clarke Coolant (part # C12E170). - Page 10 Operation & Maintenance Instructions Manual Remove the air filter elements. Turn the engine at cranking speed with the throttle control in FUEL OFF position. Use a sprayer to add a mixture of 50 percent VCI oil and 50 percent engine oil into the air inlet or turbocharger inlet.
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Page 11: Installation Instructions
Installation and Operation Data Sheets. If there is any doubt about an installation, contact should be made with Clarke Customer Support giving exact details of the problem. All installations should be clean, free of any debris and dry. Care should be taken to ensure that there is easy access to the engine for maintenance and repair. -
Page 12: Service The Engine Batteries
Operation & Maintenance Instructions Manual Pump controllers are designed and assembled to be compatible for various applications. The pump controller may have more interconnect terminals than what the engine instrument panel requires for proper operation. Only connect the terminals required by the engine instrument panel. Refer to the table below for descriptions on the interconnect terminals. -
Page 13: Connect Negative Cables
Operation & Maintenance Instructions Manual Battery Connections Reference Document C131885 Charged for 24 hours New batteries must be properly activated and charged for at least 24 hours. Undercharged batteries may cause damage to the electrical system and could prevent the engine from starting. 2.3.12. - Page 14 Operation & Maintenance Instructions Manual Retorque Connection Bolts • Driveshaft to Flywheel Adapter Disc or Torsional Coupling • Driveshaft to Pump Companion Flange MODELS DRIVE BOLT SIZE /MATERIAL TIGHTENING TOR- SHAFT GRADE QUE ft-lbs (N-m) C18H0-UFAD10, C18H0-UFAD18 C18H0-UFAD20, SC2160A M16, Class 10.9 (Metric) (Hi- 100-105 (135-142) C18H0-UFAD28 C18H0-UFAD30, C18H0-UFAD38 Tensile)
- Page 15 This measurement must be equal to the measurement at Point "H" + 1mm. Step C - Point "H" Step D - Point "J" Reinstall all guards before reconnecting the battery cables. Other Coupling Types: Consult Factory or Clarke website at www.clarkefire.com for additional information.
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Page 16: Operation
Operation & Maintenance Instructions Manual 3. Operation IMPORTANT When engine is running make sure that the coolant temperature, oil pressure and raw cooling water flow are within the limits specified on the relevant Installation & Operation Data Sheet. 3.1. TSP-E Operation Touch Screen Display Panel Status LED Mode Selector Switch... -
Page 17: Initial Starting
Operation & Maintenance Instructions Manual 3.1.1. Initial Starting • All engines accelerate rapidly to Rated Speed. Prior to the initial start, it is recommended to utilize the soft start feature to circulate coolant and lubrication oil. • It is recommended that during the initial running of the engine, since the sprinkler lines may not be completely full;... -
Page 18: Tsp-E Engine Speed Adjustment
Operation & Maintenance Instructions Manual NOTICE If the raw water is not flowing or the engine temperature is too high, open the cooling loop bypass manual valves. (applies to heat exchanger cooled engines only). • Stopping the Engine If the engine is started from pump controller use pump controller to stop the engine. If engine is started from engine instrument panel, Hold the Manual Stop. -
Page 19: Engine Over Speed
Operation & Maintenance Instructions Manual 3.1.6. Engine Over Speed In the event of an engine over speed, the ECM signals the main pump controller and initiates an engine shutdown. Should an overspeed condition occur, investigate the cause and make necessary corrections before placing engine back in service. -
Page 20: Weekly Test
Clarke recommends exercising the engine in accordance with NFPA 25’s recommendation of 30 minutes per week at a no-flow condition. 30 Minutes is enough time to ensure everything is working correctly. Clarke Fire Protection Products are designed and capable of running for long durations and high flow conditions in the event of a fire. -
Page 21: Fuel System
4. Fuel System 4.1. 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 or European Standard EN 590. Although the above referenced fuel specifications allow limited amounts of Biodiesel, 100% petroleum fuel is preferred and should be used whenever possible. -
Page 22: Bleeding The Fuel System
Figure 4. Priming Pump Figure 5. Vent Plug 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. -
Page 23: Fuel Tanks
Operation & Maintenance Instructions Manual 10. Open the fuel shut-off valve at the bottom of the fuel tank, if equipped. 11. Start the engine and check for leaks. Run the engine for 1 minute. Stop the engine and check for leaks again. 12. -
Page 24: 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 25: Crankcase Ventilation
A slight pressure is maintained within the engine crankcase compartment. Vapors are expelled through a vent pipe attached to the rocker cover. Reference Figure 8, “Crankcase Ventilation Hose” [21] Contact Clarke for an optional breather kit if vapors accumulate in your pump room. Figure 8. Crankcase Ventilation Hose... -
Page 26: Exhaust System
Operation & Maintenance Instructions Manual 5.3. 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. -
Page 27: Lubrication System
6.4. Oil Specification This engine is filled at Clarke with SAE 15W-40 oil meeting CAT ECF-3 specification. 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 28: Cooling System
• Operating Temperature The C18 has 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 indicate a high coolant temperature alarm at 217º... -
Page 29: Water
• Providing Adequate Raw Water Supply to the Engine Heat Exchanger 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 30 Operation & Maintenance Instructions Manual • Cooling Loop NOTE Engine may include a cooling loop as an optional feature and has not been evaluated by UL as part of a UL Listed fire pump driver. Figure below shows the standard NFPA 20 cooling loop piping arrangement. The cooling loop consists of an Automatic flow line with a 12V or 24V solenoid valve (HSC and ES pump applications only) that is energized to open anytime the engine is called upon to run from either the fire pump controller or from the engine instrument panel.
- Page 31 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.
- Page 32 Operation & Maintenance Instructions Manual Figure 10. Heat Exchanger Cooled Engines Figure 11. Radiator Cooled Engines • 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 33 Operation & Maintenance Instructions Manual Run the engine to verify normal operating temperature. • Cavitation Cavitation is a condition that occurs when bubbles form in the coolant flow in the low pressure areas of the cooling system and implode as they pass to the higher pressure areas of the system. This can result in damage to cooling system components, particularly the water pump impeller and cylinder liners.
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Page 34: Electrical System
Tighten mounting nut B to lock adjustment in place. 8.3. 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... -
Page 35: Maintenance
• Air Filter: check for rips, crushed elements, or extreme dirt. • Engine Crankcase Breather: check for blockages and not kinked. • Running Checks A weekly no-flow test should be performed in accordance with NFPA 25: 8.3.2 and Clarke Fire requirements. Table 6. Weekly No-Flow Test Starting Method •... -
Page 36: 6-Month Maintenance
• Inspect flexible fuel connectors at engine fuel manifold. • Inspect fuel lines, piped from fuel tank to the engine. 9.3. 1-Year Maintenance Annual flow test and maintenance should be performed in accordance with NFPA 25 8.3.3 and Clarke Fire requirements. • Static Checks Before running the engine, visual inspections, verifications, and checks should be performed in accordance with NFPA 25: 8.3.6 and Clarke Fire requirements. -
Page 37: 2-Year Maintenance
25: 8.3.3. For Diesel motor-driven pumps, do not shut down the pump until it has run for 30 minutes. 9.4. 2-Year Maintenance Two-year maintenance should be completed in accordance with Clarke Fire requirements. • 2-Year Maintenance Table 11. Maintenance - 2-Year... -
Page 38: Troubleshooting
Operation & Maintenance Instructions Manual 10. Troubleshooting Consult Clarke Service Dealer or Factory. Service dealers can be located by going to our website: www.clarkefire.com • Diagnostic Trouble Codes (DTC's) Active DTCs indicate that the failure is occurring. These types of failures are sometimes called “hard”... - Page 39 Operation & Maintenance Instructions Manual Description Corrective Action INTAKE MANIFOLD 1 AIR TEMP HIGH CHECK AIR CLEANER AFTER COOLER OR ROOM TEMP INTAKE MANIFOLD 1 TEMP VOLTAGE ABOVE NORMAL OR CHECK SENSOR AND WIRING SHORT HIGH SOURCE INTAKE MANIFOLD 1 TEMP VOLTAGE BELOW NORMAL OR CHECK SENSOR AND WIRING SHORT LOW SOURCE MANIFOLD AIR TEMP HIGH - LEAST SEVERE...
- Page 40 Operation & Maintenance Instructions Manual Description Corrective Action INJECTOR WIRING SHORTED TO BATTERY CHECK WIRING INJECTOR WIRING SHORTED TO GROUND CHECK WIRING AND INJECTOR SENSOR VOLTAGE 1 (+5 VDC) ABOVE NORMAL OR SHORT CHECK WIRING HIGH SENSOR VOLTAGE 1 (+5 VDC) BELOW NORMAL OR SHORT CHECK WIRING POWER SUPPLY LOW VOLTAGE TO INJECTORS CHECK BATTERY VOLTAGE AND WIRING...
- Page 41 Operation & Maintenance Instructions Manual Description Corrective Action INJECTOR CYLINDER 3 FUEL FLOW LOWER THAN EXPECTED INJECTOR FAILED OR FLOW LIMITER CLOSED CYLINDER #3 INJECTOR QR CODE INVALID VERIFY ACTUAL CYLINDER #3 QR CODE WITH PROGRAMMED QR CODE INJECTOR 4 LIMITED BY MAX DURATION RUN MANUAL CALIBRATION INJECTOR 4 LIMITED BY MIN DURATION RUN MANUAL CALIBRATION...
- Page 42 Operation & Maintenance Instructions Manual Description Corrective Action FUEL INJECTION PUMP CONT VALVE ERROR CHECK FUEL CONTROL VALVE SOLENOID WIR- FUEL INJECTION PUMP CONT VALVE ERROR CHECK FUEL CONTROL VALVE SOLENOID WIR- FUEL INJECTION PUMP CONT VALVE ERROR CHECK FUEL CONTROL VALVE SOLENOID WIR- FUEL INJECTION PUMP CONT VALVE ERROR CHECK FUEL CONTROL VALVE SOLENOID WIR- FUEL INJECTION PUMP CONT VALVE ERROR...
- Page 43 Operation & Maintenance Instructions Manual Description Corrective Action ENG PROT TORQUE FUEL DERATE LIMIT CONDITION EXIST CHECK FAULT CODES HYDRAULIC OIL TEMP BELOW NORMAL OPERATING RANGE WARM UP OIL HYDRAULIC OIL TEMP ABOVE NORMAL OPERATING RANGE CHECK COOLING SYSTEM, SEE OM GUIDE FAN SPEED LOW - MOST SEVERE LEVEL INSPECT FAN ASSEMBLY FAN SPEED HIGH - MODERATELY SEVERE LEVEL...
- Page 44 Operation & Maintenance Instructions Manual Description Corrective Action SENSOR VOLTAGE 2 (+5 VDC) ABOVE NORMAL OR SHORT CHECK WIRING AND SENSORS HIGH SENSOR VOLTAGE 2 (+5 VDC) BELOW NORMAL OR SHORT CHECK WIRING AND SENSORS SENSOR VOLTAGE 3 (+5 VDC) ABOVE NORMAL OR SHORT CHECK WIRING AND SENSORS HIGH SENSOR VOLTAGE 3 (+5 VDC) BELOW NORMAL OR SHORT...
- Page 45 REPROGRAM OR REPLACE ECM SECONDARY ECM FAILURE REPROGRAM OR REPLACE ECM ECM SWITCH FAILURE TEST AND REPLACE ECM SWITCH CONSULT MANUAL OR CONTACT CLARKE CONSULT MANUAL OR CONTACT CLARKE CONSULT MANUAL OR CONTACT CLARKE CONSULT MANUAL OR CONTACT CLARKE Caterpillar Specific DTC List...
- Page 46 Operation & Maintenance Instructions Manual Description Corrective Action 3509 SENSOR SUPPLY VOLTAGE 1: VOLTAGE BELOW NORMAL TROUBLESHOOTING, SENSOR SUPPLY - TEST 3510 SENSOR SUPPLY VOLTAGE 2: VOLTAGE ABOVE NORMAL TROUBLESHOOTING, SENSOR SUPPLY - TEST 3510 SENSOR SUPPLY VOLTAGE 2: VOLTAGE BELOW NORMAL TROUBLESHOOTING, SENSOR SUPPLY - TEST 3563 ENGINE INTAKE MANIFOLD #1 ABSOLUTE PRESSURE: VOLT-...
- Page 47 Operation & Maintenance Instructions Manual Description Corrective Action SYSTEM VOLTAGE LOW CHECK BATTERIES AND ALTERNATOR SYSTEM VOLTAGE INTERMITTENT / ERRATIC CHECK BATTERIES AND ALTERNATOR HIGH FUEL PRESSURE WARNING CHECK WIRING AND SENSORS CYLINDER #7 INJECTOR OPEN CIRCUIT TROUBLESHOOTING, INJECTOR SOLENOID - TEST CYLINDER #7 INJECTOR SHORT TROUBLESHOOTING, INJECTOR SOLENOID -...
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Page 48: Additional Information
11.3. Warranty 11.3.1. 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 49: Caterpillar Warranty
Operation & Maintenance Instructions Manual 11.3.3. Caterpillar Warranty... -
Page 50: Installation & Operations Data
The I&O (Installation & Operations) Data Sheet is provided inside the engine document bag shipped with the engine. The I&O Data Sheet can be downloaded on ClarkeFire.com. 11.5. Wiring Diagram Document Description C073809 TSP-E (DC Voltage) C072736 ECM Harness (DC Voltage) C073017 C18 Engine Harness (DC Voltage) C073198 Jacket Water Heater (AC Voltage) -
Page 51: Declaration Of Incorporation
Operation & Maintenance Instructions Manual 11.6. Declaration of Incorporation... - Page 52 This page is intentionally left blank.
- Page 53 This content is prepared by Clarke Fire Protection Products, INC.
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