Clarke DP Operation And Maintenance Instruction Manual

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Operation and Maintenance Instructions Manual

DP/DQ/DR/DS/DT Model Engines

C138823 -en Rev D

19 June 2024

Engines equipped with TSP-M or MECAB Instrument Panels.

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Summary of Contents for Clarke DP

Page 1 Operation and Maintenance Instructions Manual DP/DQ/DR/DS/DT Model Engines C138823 -en Rev D 19 June 2024 Engines equipped with TSP-M or MECAB Instrument Panels.
Page 3 Operation and 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 ..................3 2. Installation ........................... 6 2.1.
Page 4 12.1.3. Parts Illustration Drawing ................50 12.2. Owner Assistance ....................50 12.3. Warranty ........................ 50 12.3.1. General Warranty Statement ................50 12.3.2. Clarke Warranty .................... 50 12.3.3. Hyundai / Doosan Warranty ................50 12.4. Installation & Operations Data ..................52 12.5. Wiring Diagram ....................... 53...
Page 5 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 UK Listed/FM Approved UK Non-Listed UK Listed/Approved The Clarke 10 digit model numbers reflects the base engine type, number of cylinders, cooling system, approval listing, manufacturing location, emissions code and a power rating code. Example: DP6H-UFKAX8 • D = Doosan(Hyundai) base engine prepared by CLARKE •...
Page 7 This engine has components and fluids that reach very high operating temperatures and is provi- ded with moving pulleys and belts. 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 8 Operation and Maintenance Instructions Manual Lifting Point Air Filter Installation Rotating Parts Automatic Start Heat Exchanger Maximum Working Pressure IMPORTANT Important Note: Labels that show an exclamation mark indicate that there is a possibility of danger. Basic Rules: The following recommendations are given to reduce the risk to persons and property when an engine is in service or out of service.
Page 9 Operation and Maintenance Instructions Manual DT2H-UFAA20, DT2H-UFAA60, DT2H-UFAA98, DT2H-UFAA92, DT2H-FMAA40, DT2H-FMAAX8, DT2H-FMAAX2, DT2H- 4500 (2040) APKA90, DT2H-FMKA40, DT2H-NLAA20, DT2H-NLAA58, DT2H-NLAA50, DT2H-NLAA60, DT2H-NLAA98, DT2H-NLAA92, DT2H-UFAA48, DT2H-UFAA40, DT2H-UFAA50, DT2H-UFAA58,DT2H-UFAA88, DT2H-UFAA68, DT2H-UFKA88, DT2H-UF- KA20, DT2H-UFKA50, DT2H-UFKA58, DT2H-FMKA40, DT2H-UFKA98, DT2H-UFKA92, DT2H-UFKA60...
Page 10 Typical Installation: Radiator 2.2. Engine Storage Storing engines requires special attention. Clarke engines, as prepared for shipment, may be stored for a minimum of one year. During this period, they should be stored indoors in a dry environment. Protective coverings are recommended provided they are arranged to allow for air circulation.
Page 11 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 2.4.4. Fill the Coolant Engine is typically provided with premixed coolant installed. If engine is not provided with coolant or there is a need to top off, fill engine cooling system with Clarke Coolant C12E170. The only acceptable substitute is COOL-GARD II TY26575.
Page 13 Operation and Maintenance Instructions Manual Description Note Fuel and Water Solenoid Engine Run Signal Engine Overspeed Low Oil Pressure High Engine Temp Battery Charger Set #1 System Batt Voltage #1 Utilized by all engines. Battery Charger Set #2 System Batt Voltage #2 Start Circuit Starter #1 Start Circuit Starter #2 Main Engine Ground...
Page 14 Operation and 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. 2.4.12.
Page 15 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 16 Operation and Maintenance Instructions Manual Figure 2. Step B (Step C) To check the Vertical Parallel Offset, the driveshaft must be re-orientated. • Rotate the shaft 90° so the reference “CD” on the flywheel adapter disc or the circumference of the drive shaft flange (against the flywheel) is in the position shown on Figure 3, “Step C”...
Page 17 • Verify all driveshaft connecting bolts remain tight. Re-torque per table in section Driveshaft [10] if necessary. • Reinstall top of guard and connect negative battery cables. 2.5.2. Coupling Consult Factory or Clarke website at www.clarkefire.com for additional information.
Page 18 3. Operation 3.1. Engine Instrument Panel DP/DQ/DR/DS/DT model engines are assembled with either a MECAB instrument panel or a TSP-M [Touch Screen Panel for Mechanical Engines]. Use the illustrations provided to identify what instrument panel is installed on the engine.
Page 19 Operation and Maintenance Instructions Manual 3.3. MECAB Instrument Panel Operation 3.3.1. Operating Instructions IMPORTANT This engine is designed to operate at rated load conditions. For testing purposes, the engine can be run at lower load conditions (lower flow). Running times in any one period should not exceed 30 minutes maximum.
Page 20 Operation and Maintenance Instructions Manual IMPORTANT Do not leave the mode selector switch in the manual run position during automatic operation. The fire pump controller will be unable to stop the engine and damage may occur. Automatic Start Ensure the MECAB instrument panel mode selector switch is in the automatic / manual stop position (Figure 5, “MECAB Instrument Panel”...
Page 21 Operation and Maintenance Instructions Manual Manual Start IMPORTANT The pump controller mode selector should be in the Off position when starting from the engine panel. Ensure to return the pump controller mode to Auto after completing the manual run. To manually start the engine with the TSP controls: Position the mode selector switch to manual run.
Page 22 Operation and Maintenance Instructions Manual Figure 7. TSP-M Emergency Run Override (1) Emergency Run Override Automatic Start Ensure the TSP mode selector switch is in the automatic / manual stop position (Figure 6, “TSP-M” [16] item 1). Follow the pump controller instructions for starting the engine manually or with test features. 3.5.
Page 23 Operation and Maintenance Instructions Manual Figure 8. DP6H/DQ6H Stop Lever Figure 9. DT2H Stop Lever 3.6. Weekly Test IMPORTANT An experienced operator should always be present during the weekly test. NOTICE This engine is designed to operate at rated load conditions. For testing purposes, the engine can be run at lower load (lower flow) conditions.
Page 24 4. Fuel System 4.1. 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 diesel fuel- Specification. Although the above referenced fuel specifications allow limited amounts of Biodiesel, 100% petroleum fuel is preferred and should be used whenever possible.
Page 25 Operation and Maintenance Instructions Manual 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. DP6H, DQ6H, DR8H, DS0H, DT2H Loosen the air bleed valve (A) by hand on fuel filter head. Ref: Figure 10, “DP6H, DQ6H, DR8H, &...
Page 26 Operation and Maintenance Instructions Manual Figure 14. DS0H Figure 15. DT2H 4.3. Changing the Fuel Filter Cartridges Change the cartridges and bleed any air from the fuel system as per instructions given in Bleeding the Fuel System [20]. Fuel filter changes should take place as per recommendations and only use approved filters. It may also be necessary to change filters out with the recommendations in the event of: •...
Page 27 Operation and Maintenance Instructions Manual Engine Model Feet Meters DP, DQ DR, DS, DT 10.7 4.5. Fuel Injection Pump Components For Droop Spring and Run-Stop Solenoid (external to Injection Pump) part numbers consult factory. 4.6. Priming Pump Strainer Cleaning Clean the priming pump strainer on an annual basis. The plastic strainer is incorporated in the priming pump inlet...
Page 28 5.1. 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 29 Operation and Maintenance Instructions Manual NOTICE 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.
Page 30 Operation and Maintenance Instructions Manual 5.4. Crankcase Ventilation 5.4.1. DP6H, DQ6H - Open Crankcase Ventilation Vapors which may form within the engine are removed from the crankcase and gear train compartment by a contin- uous, pressurized ventilation system. A slight pressure is maintained within the engine crankcase compartment. Vapors expelled through a vent pipe attached to the rocker cover breather element.
Page 31 Operation and Maintenance Instructions Manual 5.5. 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 32 Operation and Maintenance Instructions Manual 6. Lubrication System 6.1. Checking Sump Oil Check the sump oil level using the dipstick on the engine as shown below. This level must always be between the dipstick marks Min. and Max. with the engine not running. DT2H, DR8H, DS0H DP6H, DQ6H 6.2.
Page 33 Operation and Maintenance Instructions Manual DT2H-UFAA60,98,92,-FMAAX8,X2 (wet exhaust manifold) Turn engine off. Put a tray under the filter to retain spilt lubricating oil. Remove the filter with a strap wrench or similar tool. Then dispose of the filter properly. DP6H DQ6H Clean the filter head.
Page 34 Operation and Maintenance Instructions Manual 6.4. Oil Specification This engine is factory-filled with oil. IMPORTANT Do not add makeup oil until the oil level is BELOW the add mark on the dipstick. Oil spec to be used for all engine models: CF-4, CG-4, CH-4 and CIH-4 are also acceptable.
Page 35 7. Cooling System 7.1. Intended Engine Operating Temperature The DP, DQ, DR, DS, & DT engines are provided with either a heat exchanger or radiator to maintain the engine coolant temperature within recommended operating guidelines. • Intended engine operating temperature:160º F (71ºC) to 185º F (85º C).
Page 36 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 37 You will find this datasheet in the documentation bag that is shipped with the engine for your specific Clarke model. This datasheet must be available during commissioning in order to set the proper minimum raw water flow. With the fire pump flowing 150% of rated flow, and the Automatic flow line open;...
Page 38 When this occurs you have no fire protection! Clarke recommends that after the initial engine commissioning and also prior to each weekly exercise of the engine / fire pump set, both strainers be removed and cleaned and then re-installed before starting the engine.
Page 39 Operation and Maintenance Instructions Manual • Improper Coolant • Restricted coolant flow cause by collapsed hose or plugged system • Coolant fill cap is loose or unable to retain the required pressure • Insufficient fluid level • Failure to de-aerate •...
Page 40 Operation and Maintenance Instructions Manual Figure 19. DT2H-UFAA60,98, 92, -FMAAX8, X2 - Cooling System Flow Path...
Page 41 Operation and Maintenance Instructions Manual 8. Electrical System 8.1. Wiring Diagram Instrument Panel Description Document TSP-M* C073082 MECAB Instrument Panel C071842 *Refer to TSP-M Operators Manual for more information: C138534 8.2. 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 42 Operation and Maintenance Instructions Manual 8.3.1. MECAB Instrument Panel Over Speed The OVERSPEED RESET (Figure 3-3 item 6) switch is included on the instrument panel. Should an overspeed condition occur, investigate the cause and make necessary corrections before placing engine back in service. The OVERSPEED RESET must be manually lifted for two (2) seconds to reset.
Page 43 “OVERSPEED SHUTDOWN” lamp on the outside of the Clarke instrument panel (Figure 8-4) and a red LED located on the middle of the speed switch inside of the Clarke instrument panel (Figure 8-5). In addition to these flashing status lamps, a “Low Engine Coolant Temperature Alarm” is sent via engine / fire pump controller inter-connect circuit #312 as a means to alert the user outside of the engine room.
Page 44 • Five (5) Blinks Electrical Current Exceeds 10 Amps on Alarm Circuits: Status lamps will flash two 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 45 Follow over speed verification steps per section 8.3. • Low Oil Pressure DP, DQ, DR, DS: With the engine running, jumper the engine mounted low oil pressure switch at terminal “WK” to “GROUND”. DT only: With the engine running, jumper the engine mounted Low Oil Pressure switch. Wait for 15 seconds and controller alarm will activate.
Page 46 A mechanical governor controls the engine speed. The governor is built into the fuel injection pump. All governors are adjusted to the rated speed at nameplate power or maximum allowed pump load before leaving Clarke. During Start-Up Inspection or when placing reconditioned units into service, some minor speed adjustment may be required.
Page 47 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. The PDF can be downloaded from ClarkeFire.com...
Page 48 • Replace the Lubricating Oil. • Replace the Coolant. • Use Clarke Coolant (part # C12E170). The only acceptable substitute is COOL-GARD II (part # TY26575). • Check the Mounting Isolators and foundation nuts. • Mounting Isolators: If applicable •...
Page 49 • Cleaning Kit number: 0C12E280 (Includes: Handle 0C12E278, Rod 0C12E281, Brush 0C12E279 and De-scaler liquid 5 gal. 0C12E77). • Engine Coolant. • Use Clarke Coolant (part # C12E170). The only acceptable substitute is COOL-GARD II (part # TY26575). 9.7.2. NSR Maintenance Preparation Lockout the engine.
Page 50 Figure 22. NSR Heat Exchanger End Caps • Refill the engine coolant. Use Clarke Coolant (part # C12E170). The only acceptable substitute is COOL-GARD II (part # 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 51 Operation and Maintenance Instructions Manual NOTICE If you suspect there is a leak in the heat exchanger, pressure testing the assembly may be required. For details on pressure testing the NSR contact Clarke Fire customer support.
Page 52 Operation and Maintenance Instructions Manual 10. Troubleshooting • Consult Clarke Service Dealer or Factory • Service dealers can be located by going to our website: www.clarkefire.com. • TSP-M Troubleshooting • For trouble shooting pertaining to the Touch Screen Panel for Mechanical Engines (TSP-M) refer to the TSP-M...
Page 53 Operation and Maintenance Instructions Manual 11. Parts Information 11.1. Spare Parts To ensure best operation and efficiency of all engine components, always use genuine Clarke spare parts. Contact a local Clarke Service Dealer for parts pricing and availability. • Service Dealer Locator: Clarkefire.com/home/service/service-providers/service-dealer-locator •...
Page 54 12.3. Warranty 12.3.1. 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 55 Operation and Maintenance Instructions Manual WARRANTY POLICY SUPPLIER’s liability under this warranty shall be IN LIEU OF ALL OTHER LIABILITIES OF SUPPLIER for defect in material or workmanship of Products or ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, statutory or at common law WHICH BUYER HEREBY WAIVES. In no event shall SUPPLIER be liable for consequential or indirect damages regarding Products or End-Products.
Page 56 Operation and Maintenance Instructions Manual SUPPLIER and BUYER respectively shall have the following responsibilities in respect of defect in materials or workmanship covered by the warranty: Warranty will be only applied for Engines for which SUPPLIER has received the warranty claim report or the equivalent written information when any Engines are delivered to the first customer. SUPPLIER will compensate BUYER the genuine parts expenses used for replacing the defective parts under Warranty.
Page 57 Operation and Maintenance Instructions Manual 12.5. Wiring Diagram Instrument Panel Description Document TSP-M C073082 MECAB Instrument Panel C071842 12.6. Declaration of Incorporation...
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Page 59 This content is prepared by Clarke Fire Protection Products, INC.

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