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Clarke DP6H-APKA60, Operation And Maintenance Instruction Manual

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Clarke DP6H-APKA60 Operation And Maintenance Instruction Manual Download Page 48

 

 

Page 48 of 49 

 
 

Appendix “A” (continued) 

 

DR8H, DS0H, & DT2H (DRY EXHAUST MANIFOLD) ENGINE MODELS 

 

Clarke Engine Models 

DR8H 

DS0H 

DT2H-UFAA20,          
DT2H-UFKA20,         

DT2H-FMAA40,         
DT2H-FMKA40,          

DT2H-UFAA58,          

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. A 

Fuel Filter (Primary) 

C02736 R. A 

Air Filter 

C03749 R. A 

C03244 R. C 

Alternator 

C072095 

Fuel Injection Pump 

C02913 

C02914 

C02915 

Heat Exchanger 

C051529 R. D 

C051389 R. B 

C051389 R. B 

Starter Motor (12V) 

N/A 

Starter Motor (24V) 

C072096 

Switch, Oil Pressure 

C07645 R. C OR C071273 R. A OR C071614 R. A OR C071884 R.A OR 

C072011 OR C072013 

Switch, Speed 

C071963 R.A 

Switch, Coolant Temperature 

INCLUDED IN C071963 R. A SPEED SWITCH OR C071881 R.A 

Thermistor 

C071607 R. A OR C051749 R. B 

Turbocharger 

C061648 

 (RIGHT) 

C061649 

 (LEFT) 

C061650 
(RIGHT) 
C061651 

 (LEFT) 

C061652 

 (RIGHT) 

 C061653 

(LEFT) 

Thermostat 

C051568 

Nozzle, Injector 

C02792 

 
 
 
 
 
 

Summary of Contents for DP6H-APKA60

Page 1: ...S 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 FAX 44 0 1236 427274 TELE 1 513 771 2200 Ext 427 FAX 1 513 771 5375 www clarkefire com ...

Page 2: ...l Pneumatic Starting System 17 2 5 2 To Stop Engine 18 2 5 3 Emergency Stop Instructions 18 2 6 WEEKLY TEST 18 3 0 ENGINE SYSTEMS 19 3 1 FUEL SYSTEM 19 3 1 1 Diesel Fuel Specification 19 3 1 2 Bleeding the Fuel System 20 3 1 3 Changing Fuel Filter Cartridge 21 3 1 3 1 Fuel Filters 21 3 1 4 Fuel Tanks 22 3 1 5 Fuel Injection Pump Components 22 3 1 6 Priming Pump Strainer Cleaning 22 3 2 AIR EXHAUST...

Page 3: ...at Exchanger or CAC 32 3 4 7 6 Backflow Preventers 32 3 4 7 7 Raw Water Outlet Temperature 32 3 4 8 Flow Paths of Engine Cooling System 32 3 4 9 Important Service Notice 34 3 4 9 1 Water Pump Cavitation 34 3 5 ELECTRICAL SYSTEM 34 3 5 1 Wiring Diagrams 34 3 5 2 Checking Drive Belt Tension and Adjustment 35 3 5 3 Speed Switch 35 3 5 4 Magnetic Pick Up 36 3 5 5 Mechanical Engine Control and Alarm Bo...

Page 4: ... of the following languages Spanish French German Italian NOTE The information contained in this book is intended to assist operating personnel by providing information on the characteristics of the purchased equipment 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 t...

Page 5: ... by CLARKE The term Machine refers to any piece of equipment with which the engine might interface This manual provides all the information necessary to operate your newly acquired engine safely and efficiently and perform routine servicing correctly Please read it carefully MODEL NUMBERING IDENTIFICATION There are two identification plates attached to each engine Clarke Identification Plate Engin...

Page 6: ...hine using a Clarke engine to optimize the application in terms of maximum end user safety 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 Engines must not be used for applications other than those declared under Scope of Supply Incorrect handling modifications and use of non original parts may affect saf...

Page 7: ...0 DT2H UFAA50 DT2H UFAA58 DT2H UFAA88 DT2H UFAA68 DT2H UFKA88 DT2H UFKA20 DT2H UFKA50 DT2H UFKA58 DT2H FMKA40 DT2H UFKA98 DT2H UFKA92 DT2H UFKA60 4500 2040 Figure 2 Figure 3 shows the typical lifting arrangement of a bare engine Note the lifting points on the engine are for lifting the ENGINE only Caution when lifting lift point should always be over the equipment Center of Gravity Figure 3 Figure...

Page 8: ...y EMC Generic standards Immunity for industrial environments EN 55011 2016 A1 2017 Industrial scientific and medical equipment Radio frequency disturbance characteristics Limits and methods of measurement A technical file for the product listed above has been compiled in accordance with part B of Annex Vii of the Machinery Directive 2006 42 EC and Annex III of Low Voltage Directive 2014 35 EU The ...

Page 9: ...light flames turn on lights or activate electric bells or telephones so as to avoid explosions Take the victim to a ventilated area or into the open air placing him on his side if he is unconscious CAUSTIC BURNS 1 Caustic burns to the skin are caused by acid escaping from the batteries remove the clothes wash with running water being careful not to affect injury free areas 2 Caustic burns to the e...

Page 10: ...ket Water Heater Voltage Air Filter Installation 2 0 INSTALLATION OPERATION 2 1 TYPICAL INSTALLATION A typical Fire Pump installation is shown in Figures 6 6A 1 Pump Engine set 2 Main Pump Controller 3 Pump discharge 4 Air louver 5 Entrance door with air louver 6 Exhaust silencer 7 Exhaust system supports 8 Exhaust outlet pipe 9 Concrete base 10 Exhaust flexible connection joint pipe 11 Air Discha...

Page 11: ...nt plugs and install coolant in the normal mix percentage of 50 coolant 50 water premixed 5 Remove the protection from the intake and exhaust openings 6 Prepare a preservative fuel container as a fuel source using a fuel conditioner mixture of C02686 or C02687 with ONLY Diesel 2 fuel or Red diesel fuel ASTM D 975 or BS2869 Class A2 Refer to Section 3 1 1 for Fuel Specification 7 Disconnect the cou...

Page 12: ...Tube 4 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 premixed 50 water 50 coolant solution Use only coolants meeting ASTM D6210 specifications for heavy duty diesel engines Never use light duty or automotive coolants in the engine that are stated as ASTM D3306 only Refer to Figure 23...

Page 13: ...ations this engine must be registered to the final installation name and address To register this engine go to www clarkefire com and select Warranty Registration 2 4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 2 4 1 Listed Driveshafts Refer to Listed Driveshaft Installation Operation and Maintenance Manual C132355 2 4 2 Driveshaft To check the alignment of the pump shaft and engine cranksha...

Page 14: ...AB on the flywheel adapter disc or the circumference of the drive shaft flange against the flywheel adapter disc is in the 12 o clock position shown on figure 7a 2 Measure from the face of the flywheel adapter disc to point E Point E is on the bearing bore as shown in Figure 7a This measurement must be Measurement Driveshaft 109 2mm SC81A CDS50 SC 123 5 1 5mm SC2160A 142 5 1 5mm SC2390 SC2390A Fig...

Page 15: ...t Factory or Clarke website at www clarkefire com for additional information 2 5 STARTING STOPPING THE ENGINE 2 5 1 To Start Engine Before starting the engine for the first time review section 3 4 6 to ensure there is an adequate Raw Water Supply to the Engine Heat Exchanger On UL FM engines use main pump controller for starting and stopping the engine Should the main pump controller become inoper...

Page 16: ...d Indication Light 3 Manual Crank Controls 8 Oil Pressure Gauge 4 Overspeed Reset 9 Voltmeters Battery 1 2 5 Manual Mode Warning Light 10 Coolant Temperature Gauge Non Listed Instrument Panel 1 Emergency Operating Instructions 4 Overspeed Reset 2 Automatic Manual Mode Selector 5 Warning Light 3 Manual Crank Controls 6 Overspeed Verification 5 7 4 1 3 6 8 9 9 10 2 ...

Page 17: ...on main pump controller and engine gauge panel to AUTOMATIC after completing manual run 2 5 1 1 Optional Pneumatic Starting System Some engines may be provided with an optional pneumatic starting system to crank the engine from a pressurized receiver tank See figure 9A for schematic of the pneumatic starter system and wiring diagram for field wiring ...

Page 18: ... engine rotate the emergency stop lever until it stops Continue to hold lever in STOP position until engine comes to a complete stop DT2H engine models If energized to stop solenoid fails you will NOT be able to stop the engine from the instrument control panel or fire pump controller This solenoid is located on the left side opposite side of instrument panel of the engine towards the front To sto...

Page 19: ...ements for fuel maintenance for all Clarke fire pump engine installations The following is reprinted from the NFPA 25 2014 Standard for the Inspection Testing and maintenance of Water Based Fire Protection Systems Copyright 2013 National Fire Protection Association All Rights Reserved 8 3 4 Diesel Fuel Testing and Maintenance 8 3 4 1 Diesel fuel shall be tested for degradation no less than annuall...

Page 20: ...ro organisms and particulates or destabilization active fuel maintenance systems permanently installed on the fuel storage tanks have proven to be successful at maintaining fuel quality An active fuel maintenance system will maintain the fuel quality in the tank therefore preventing the fuel from going through possible cycles of degradation risking engine reliability and then requiring recondition...

Page 21: ... engine has had an overhaul 2 The quality of the fuel is questionable 3 The engine has been subjected to temporary adverse conditions outwith it normal operating parameters 4 The fuel tank condensation trap has not been drained in line with manufacturer s recommendations 3 1 3 1 Fuel Filters Note DT2H UFAA60 98 92 FMAAX8 X2 wet exhaust manifold engines are provided with parallel duplex fuel filter...

Page 22: ...ir and rinse it with fuel 3 2 AIR EXHAUST SYSTEM 3 2 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 3 2 2 Ventilation The engine must be provided with adequate venti...

Page 23: ...o personnel and major internal engine damage could occur should any foreign matter be drawn into the engine The air cleaner manufacturer recommends the following 1 The pre oiled reusable elements are serviced with a special oil The elements can be serviced or replaced 2 Figure 15 shows the air filter service instructions 3 When servicing the element is not practical you can improve filter efficien...

Page 24: ...m within the engine are removed from the crankcase and gear train compartment by a continuous 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 Ref Figure 16 Figure 16 3 2 4 2 DR8H DS0H DT2H Crankcase Ventilation System A crankcase ventilation system allows for the...

Page 25: ...92 24 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 and minimize vibration Protection against entry of water and other foreign matter While the engine is running inspect exhaust pipe outlet outside of the pump room itself for environmental hazards such as excessive smoke...

Page 26: ...ter 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 Refer to Figure 14 Figure 14 DT2H UFAA60 98 92 FMAAX8 X2 wet exhaust manifold Figure 14 DQ6H Note On DQ engines drai...

Page 27: ...are also acceptable Figure 20 3 3 5 Oil Capacities Including Filter ENGINE MODEL OIL CAPACITY QUARTS LITERS DP6 All Models 19 8 18 7 DQ6 All Models 26 9 25 5 DR8 All Models 28 5 27 0 DS0H DS0R All Models 34 9 33 0 DT2H UFAA20 40 50 58 88 39 1 37 0 DT2H UFAA60 98 92 FMAAX8 X2 35 4 33 5 DT2R UFAA19 49 39 1 37 0 Figure 21 3 4 COOLING SYSTEM 3 4 1 Intended Engine Operating Temperature The DP DQ DR DS ...

Page 28: ...ids Max 340 20 Total Hardness Max 170 10 Figure 22 3 4 4 Coolant Capacities Ethylene Glycol or Propylene Glycol are acceptable IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives Do not mix ethylene glycol and propylene glycol base coolants Do not use coolants that contain nitrites Use an ethylene glycol coolant low silicate formulation that meets th...

Page 29: ...g with a pre mix solution Note On DT2H engines it is important to loosen the bolts in the banjo connections at the top of each turbo to provide a vent during the fill Once the initial fill is complete the bolts should be tightened and then follow the partial fill instructions below Figure 25A Caution Do not overfill cooling system A pressurized system needs space for heat expansion without overflo...

Page 30: ...Manual by pass line and it can be opened at any time if for any reason the engine shows signs of overheating Each line has two quarter turn shutoff values installed and the normal position of the shutoff valve is to remain open in the Automatic flow line and remain closed in the Manual by pass flow line NOTE Opening up both lines to flow is never a problem should there be some concern of engine ov...

Page 31: ...need to capture the flow for a specific amount of time coming out of the heat exchanger and going to a floor drain in order to establish a reasonably accurate flow rate value Using a container or bucket of known volume record the time required to fill the container and compare to the gpm or L min value provided on the I O datasheet THIS IS CRITICAL FOR PROPER ENGINE COOLING AT MAXIMUM PUMP LOAD If...

Page 32: ...weekly exercise of the engine fire pump set both strainers be removed and cleaned and then re installed before starting the engine 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 Figures 26 and 26A1 for location of sensors A circuit board located near the front of ...

Page 33: ...f 49 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 34: ...ation 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 Cavitation in an engine can be caused by Improper coolant Restricted coolant flow caused by collapsed...

Page 35: ...cur 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 NOTE This reset operation must be completed to allow a restart If not the engine will not start thru the main pump controller or manually OVERSPEED VERIFICATION Hold the OVERSPEED VERIFICATION switch in the up position This will provi...

Page 36: ...panel Figure 30 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 NOTE When first applying battery power to the engine or after activating the overspeed reset switch the OVERSPEED SHUTDOWN lamp and red LED on the speed switch will flash several t...

Page 37: ...els Figure 32B Figure 32A DP6H DQ6H engine models Figure 32B DR8H DS0H models Figure 32C DT2H engine models On the Clarke instrument panel operate the OVERSPEED RESET switch for four 4 seconds and release Refer to Figure 31 The INITIALIZATION PATTERN will flash This is normal The continuous three 3 blink flash sequence should turn off at this point If problem still exists replace engine coolant te...

Page 38: ...d Proceed to engine speed sensor check below Engine speed sensor magnetic pick up check Verify wiring and connector at engine speed sensor are secure Magnetic pick up is located on the right side of the engine on the flywheel housing Figure 35 Figure 35 With engine running verify that the tachometer is functioning normally Refer to section 3 5 4 of Engine Operator s Manual to properly reposition t...

Page 39: ...ge Figure 36 3 5 7 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 1400 Reserve Capacity minutes 430 Refer to Clarke drawing see Page 5 for additional information on Clarke supplied batteries 3 6 ENGINE SPEED ADJUSTMENT A mechanical governor controls the engine speed The go...

Page 40: ...Fuel Tank General Inspection Governor Run Stop Control Jacket Water Heater Lubrication Oil Level Operating Gauges Remove Water from Fuel Filter Run Engine Warning Light Cooling Water Strainers Clean Radiator Core Debris if equipped EVERY 6 MONTHS Batteries Battery Charging Alternator Belt tension Coolant Protection Level Driveshaft U Joints Fuel Lines EVERY 1 YEAR Air Cleaner Fuel Priming Pump Str...

Page 41: ...urray clarkefire com 6 2 ENGINE MAINTENANCE PARTS LIST Refer to Appendix A at the end of this manual ENGINE Air Filter Service Air Filter Oil MODEL Kit All 99 55050 C121157 Figure 39 7 0 OWNER ASSISTANCE Consult Clarke Service Dealer or Factory Service Dealers can be located by going to our website www clarkefire com 8 0 WARRANTY 8 1 GENERAL WARRANTY STATEMENT The satisfactory performance of Clark...

Page 42: ... for the duration of the utility power outage NO OVERLOAD capability is available for this rating Under no condition is an engine to operate in parallel with the public utility at the Fire PUMP POWER rating This rating should be applied where reliable utility power is available A Fire Pump rated engine should be sized for a maximum of 70 average load factor and 200 hours of operation per year When...

Page 43: ...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 BUYER shall carry out all repairs and the fitting of all replacement parts covered by the Warranty and SUPPLIER will compensate BUYER the net labor expenses involved in the same at an ...

Page 44: ...der this Article have been verified by SUPPLIER upon request of BUYER SUPPLIER will deliver free of charge such parts as are determined to be missing or damaged BUYER shall be responsible for the proper storage and maintenance not be decrease the performance of the Engines during the period of time from unloading of Engines by the carrier of Port of Destination until delivered to the first custome...

Page 45: ...g ENGINE COVERAGE MONTHS from Shipping date MONTHS from Delivery Date Engine Hours Fire Pump 0 24 0 18 200 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: ...ir Cleaner 12 22 23 40 43 Fuel 11 12 19 20 21 40 Lubricating Oil 26 40 Fuel Specifications 19 Fuel System Operation 12 19 20 21 39 Bleeding 20 Pump Injection 18 22 39 Service 19 20 34 41 42 43 44 G Governor Speed Adjustment Subject Page I Installation Data Installation Instructions 11 L Lube Oil Recommendations 27 Lubricating Oil Volume 27 Lubricating System 25 M Magnetic Pickup 36 Maintenance Sch...

Page 47: ... Secondary N A Air Filter C03749 C03244 Alternator C072092 C072093 Fuel Injection Pump C02911 C02912 Heat Exchanger C051529 Starter Motor 12V N A Starter Motor 24V C072094 Switch Oil Pressure C07645 or C071884 Switch Speed C071571 Switch Coolant Temperature INCLUDED IN C071571 SPEED SWITCH or C071881 Thermistor C071607 or C051749 Turbocharger C061646 C061647 Thermostat C051718 C051568 Nozzle Injec...

Page 48: ... Air Filter C03749 R A C03244 R C Alternator C072095 Fuel Injection Pump C02913 C02914 C02915 Heat Exchanger C051529 R D C051389 R B C051389 R B Starter Motor 12V N A Starter Motor 24V C072096 Switch Oil Pressure C07645 R C OR C071273 R A OR C071614 R A OR C071884 R A OR C072011 OR C072013 Switch Speed C071963 R A Switch Coolant Temperature INCLUDED IN C071963 R A SPEED SWITCH OR C071881 R A Therm...

Page 49: ...n Oil Filter C04569 4 Fuel Filter Primary C02736 4 Fuel Filter Secondary N A Air Filter C03707 2 Alternator C072097 Fuel Injection Pump C02916 Heat Exchanger C052066 Starter Motor 24V C072098 Switch Oil Pressure C071614 or C071884 Switch Speed C071273 Switch Coolant Temperature INCLUDED IN C071571 SPEED SWITCH or C071881 Thermistor C071607 or C051749 Turbocharger C061654 Thermostat C051568 Nozzle ...

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