Operation and Maintenance

Instructions Manual
KA4H MODEL ENGINES
FOR
FIRE PUMP APPLICATIONS

Clarke Fire Protection Products, 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 TELE: +1-513-475-3473
FAX: +44(0)1236 427274 FAX: +1.513.771.5375

www.clarkefire.com

11/19/18
C136235 revH
 CONTENTS

SUBJECT PAGE
1.0  Introduction ..............................................................................................................................4 
1.1  Identification/Nameplate .........................................................................................................4 
1.2  Safety/Caution/Warnings ........................................................................................................5 
2.0  Installation/Operation .............................................................................................................8 
2.1  Typical Installation..................................................................................................................8 
2.2  Engine Storage ........................................................................................................................9 
2.2.1  Storage Less Than 1 Year ...............................................................................................9 
2.2.2  Extended Storage Maintenance Procedure ......................................................................9 
2.3  Installation Instructions .........................................................................................................10 
2.4  Specific Flywheel Coupling ..................................................................................................11 
2.4.1  Listed Driveshafts..........................................................................................................11 
2.4.2  Driveshaft ......................................................................................................................11 
2.4.3  Other Coupling Types ...................................................................................................12 
2.5  Weekly Test...........................................................................................................................12 
2.6  Starting/Stopping The Engine ...............................................................................................13 
2.6.1  To Start Engine:.............................................................................................................13 
2.6.2  To Stop Engine ..............................................................................................................14 
2.6.3  Emergency Stop Instructions.........................................................................................14 
3.0  Engine Systems .......................................................................................................................15 
3.1  Fuel System ...........................................................................................................................15 
3.1.1  Diesel Fuel Specification...............................................................................................15 
3.1.2  Bleeding The Fuel System ............................................................................................16 
3.1.3  Changing The Fuel Filter Cartridges .............................................................................16 
3.1.4  Fuel Tanks .....................................................................................................................17 
3.1.5  Ka4h Fuel Injection Pump Components .......................................................................17 
3.2  Air/Exhaust System ...............................................................................................................17 
3.2.1  Ambient Conditions ......................................................................................................17 
3.2.2  Ventilation .....................................................................................................................17 
3.2.3  Standard Air Cleaner .....................................................................................................17 
3.2.4  Crankcase Ventilation ...................................................................................................18 
3.2.5  Exhaust System .............................................................................................................18 
3.3  Lubrication System ...............................................................................................................19 
3.3.1  Checking Sump Oil .......................................................................................................19 
3.3.2  Changing Engine Oil .....................................................................................................19 
3.3.3  Changing Oil Filter Cartridge........................................................................................19 
3.3.4  Oil Specification ............................................................................................................19 
3.3.5  Oil Capacities (Including Filter)....................................................................................20 
3.4  Cooling System .....................................................................................................................20 
3.4.1  Intended Engine Operating Temperature ......................................................................20 
3.4.2  Engine Coolant ..............................................................................................................20 
3.4.3  Water .............................................................................................................................20 
3.4.4  Coolant Capacities .........................................................................................................20 
3.4.5  Coolant Inhibitor ...........................................................................................................21 
3.4.6  Procedure For Filling Engine ........................................................................................21 

Page 2 of 35
 3.4.7  Providing Adequate Raw Water Supply To The Engine Heat Exchanger ....................22 
3.4.7.1  Raw Water Supply ..................................................................................................22 
3.4.7.2  Cooling Loop ..........................................................................................................22 
3.4.7.3  Setting Raw Water Flow Rate ................................................................................23 
3.4.7.4  Raw Water Outlet ...................................................................................................24 
3.4.7.5  Raw Water Quality, Strainers And Deterioration Of Heat Exchanger (Or Cac) ....24 
3.4.7.6  Backflow Preventers ...............................................................................................24 
3.4.7.7  Raw Water Outlet Temperature ..............................................................................25 
3.4.8  Flow Paths Of Engine Cooling System .........................................................................25 
3.4.9  Important Service Notice...............................................................................................25 
3.4.9.1  Water Pump Cavitation ..........................................................................................25 
3.5  Electrical System ...................................................................................................................26 
3.5.1  Wiring Diagrams (Only With Engine Gauge Panel) .....................................................26 
3.5.2  Checking Drive Belt Tension And Adjustment ............................................................26 
3.5.3  Speed Switch (When Supplied) .....................................................................................26 
3.5.4  Magnetic Pick-Up (When Supplied) .............................................................................27 
3.5.5  Mechanical Engine Control And Alarm Board (Mecab) Speed Switch
Troubleshooting ...........................................................................................................................27 
3.5.6  Field Simulation Of Pump Controller Alarms ..............................................................29 
3.5.7  Battery Requirements ....................................................................................................30 
3.6  Engine Speed Adjustment .....................................................................................................30 
4.0  Maintenance Schedule ...........................................................................................................30 
4.1  Routine Maintenance.............................................................................................................30 
5.0  Trouble Shooting....................................................................................................................31 
6.0  Parts Information...................................................................................................................31 
6.1  Spare Parts .............................................................................................................................31 
6.2  Engine Maintenance Parts List ..............................................................................................31 
7.0  Owner Assistance ...................................................................................................................31 
8.0  Warranty ................................................................................................................................31 
8.1  General Warranty Statement .................................................................................................31 
8.2  Clarke Warranty ....................................................................................................................31 
8.3  Warranty Period ....................................................................................................................32 
8.3.1  Exclusions: ....................................................................................................................32 
8.3.2  To Obtain Warranty Service: ........................................................................................32 
8.3.3  Coverage ........................................................................................................................32 
9.0  Installation & Operation Data ..............................................................................................33 
10.0  Wiring Diagrams....................................................................................................................33 
11.0  Parts Illustration Drawing ....................................................................................................33 
12.0  Appendix (Alpha Index) ........................................................................................................34 

Check factory availability for manuals in other languages.

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 to update the contents of this publication without
notice.
Page 3 of 35
1.0 INTRODUCTION MODEL NUMBERING & IDENTIFICATION

SCOPE OF SUPPLY There are two identification plates attached to each

engine. Clarke Identification Plate: Engine Model,
The following paragraphs summarize the “Scope of Serial Number, Rating and Date of Manufacture are
Supply” of the Engine: shown on this identification plate. The KA4H Series
identification plate is mounted on the brace under the
 The CLARKE Engine supplied has been instrument panel.
designed for the sole purpose of driving a
stationary Emergency Fire Pump. It must not Note that there are two types of identification plates,
be used for any other purpose. dependent on whether the engine is a “Non-Listed”,
“Listed/Approved”. These are typical examples. (See
 Shall not be subjected to Horsepower Figure #1).
requirements greater than the certified
nameplate rating (for UL/cUL/FM only). Clarke Identification Plates

 Engines must be sized to cover fully the UK Non-Listed UK Listed/Approved

maximum power absorbed by any particular
driven equipment together with a safety
factor on no less than 10%. (For Non-listed
only).

 Derates for elevation and temperature need to

be considered for maximum pump power.

 Fuel delivery settings are factory set with-in

the injection pump and must not be tampered
with or adjusted. Minor RPM adjustments to
meet pump requirements are permissible.

 The engine shall be installed and maintained

in accordance with the guidelines stated in
this manual.
Figure #1
 Periodic running checks to ensure
functionality should be kept to a maximum of The Clarke 10 digit model numbers reflects the base
½ hour per week. engine type, number of cylinders, cooling system,
approval listing, manufacturing location, emissions
1.1 IDENTIFICATION/NAMEPLATE code and a power rating code.
Example: KA4H-UFKA24
 Throughout this manual, the terms “Engine”  K = Base engine.
and “Machine” are used.  A = Base engine family (2.5 liter 4 cylinder)
 4 = Number of cylinders
 The term “Engine” refers solely to the diesel  H = Heat Exchanger cooled
engine driver as supplied by CLARKE.  UF = Underwriters Laboratories Listed/
Factory Mutual Approved, UL =
 The term “Machine” refers to any piece of Underwriters Laboratories Listed, NL =
equipment with which the engine might Non-Listed
interface.  K=Manufacturing Location (A= Cincinnati,
This manual provides all the information necessary to K= Coatbridge)
operate your newly acquired engine safely and  A= Non-Emissionized
efficiently, and perform routine servicing correctly.  24 = Power rating code
Please read it carefully.

Page 4 of 35
1.2 SAFETY/CAUTION/WARNINGS Figure #4 shows the typical lifting arrangement of a
base mounted engine and pump set when the base (or
ATTENTION: This engine has components and module) is furnished with lifting holes.
fluids that reach very high operating temperatures
and is provided 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.

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”.
Figure #4
Incorrect handling, modifications and use of non-
original parts may affect safety. When lifting the When Clarke furnishes the base (or module) for the
engine, take care to use suitable equipment to be engine and pump set, the combined weight of the
applied to the points specially provided as shown on engine and base (or module) will be indicated on the
the appropriate Engine Installation Drawing. Engine unit. Caution, when lifting, lift point should
weights are shown in figure #2 always be over the equipment Center of Gravity.

ENGINE MODEL WEIGHT lbs (kg) Note: The engine produces a noise level exceeding
KA4H-UFKA24, 34 748 (339) 70 dB(a). When performing the weekly functional
Figure #2 test, it is recommended that hearing protection be
worn by operating personnel.
Figure #3 shows the typical lifting arrangement of a
bare engine. Note the lifting points on the engine are CLARKE UK provides the machine manufacturer
for lifting the engine only. Caution, when lifting, lift with a “Declaration of Incorporation” for the Engine,
point should always be over the equipment Center of when required, a copy of which is enclosed in the
Gravity. manual. This document clearly states the machine
manufacturers’ duties and responsibilities with
respect to health and safety. Refer to Figure #5.

Figure #3
Page 5 of 35
 GRANGE WORKS, LOMOND ROAD, COATBRIDGE, UNITED KINGDOM, ML5 2NN
TEL: 0044 1236 429946 FAX: 0044 1236 427274

DECLARATION OF INCORPORATION

We hereby declare that the engine is intended to be incorporated into other machinery and must not be put
into service until the relevant machinery, into which the engine is to be incorporated, has been declared in
conformity with the essential health and safety requirements of the Machinery Directive 2006/42/EC and
consequently the conditions required for the CE Mark.

We declare that the engine is manufactured in accordance with the following Standards and Directives:
Machinery Directive 2006/42/EC
Low Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU
Standards:
EN ISO 12100:2010 - Safety of machinery. General principles for design. Risk assessment and risk
reduction
EN 60204-1:2006+A1:2009 - Safety of machinery. Electrical equipment of machines. General
requirements
EN 61000-6-2:2005 - Electromagnetic compatibility (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

1) Description – Diesel Engines

Manufacturer – Clarke Fire Protection Products Ltd
Model Number –
Serial Number –
Year of Manufacture –
Contract Number –
Customer Order Number –

2) The engine has moving parts, areas of high temperatures and high temperature fluids under pressure. In
addition, it has an electrical system which may be under strong current.
3) The engine produces harmful gases, noise and vibration and it is necessary to take suitable precautionary
measures when moving, installing and operating the engine to reduce risk associated with the
characteristics stated above.
4) The engine must be installed in accordance with local laws and regulations. The engine must not be
started and operated before the machinery into which it is to be incorporated and/or its overall
installation has been made to comply with local laws and regulations. The engine must only be used in
accordance with the scope of supply and the intended applications.

Signed _________________________________ Date:____________________

John Blackwood – Managing Director

REGISTERED IN SCOTLAND NO: 81670 C130896, Rev. N 25Sept18 

Figure #5
Page 6 of 35
WHAT TO DO IN AN EMERGENCY Take the victim to a ventilated area or into the open
air, placing him on his side if he is unconscious.
Any user of the Engine who follows the instructions
set out in this manual, and complies with the CAUSTIC BURNS
instructions on the labels affixed to the engine are
working in safe conditions. 1) Caustic burns to the skin are caused by acid
escaping from the batteries:
If operating mistakes cause accidents call for help  remove the clothes
immediately from the EMERGENCY SERVICES.  wash with running water, being
In the event of an emergency and while awaiting the careful not to affect injury-free areas
arrival of the EMERGENCY SERVICES, the 2) Caustic burns to the eyes are caused by
following general advice is given for the provision of battery acid, lubricating oil and diesel fuel.
first aid.  Wash the eye with running water for
at least 20 minutes, keeping the
FIRE eyelids open so that the water runs
over the eyeball and moving the eye
Put out the fire using extinguishers recommended by in all directions.
the manufacturer of the machine or the installation.
ELECTROCUTION
BURNS
1) Put out the flames on the clothing of the Electrocution can be caused by:
burns victim by means of: 1) The engine’s electrical system (12/24
 drenching with water VDC)
 use of powder extinguisher, making 2) The electrical coolant pre-heating system
sure not to direct the jets onto the 120/240 Volt AC (if supplied) AC current.
face
 blankets or rolling the victim on the In the first case, the low voltage does not involve
ground high current flows through the human body;
2) Do not pull off strips of clothing that are however, if there is a short circuit, caused by a metal
sticking to the skin. tool, sparks and burns may occur.
3) In the case of scalding with liquids, remove In the second case, the high voltage causes strong
the soaked clothing quickly but carefully. currents, which can be dangerous.
4) Cover the burn with a special anti-burn If this happens, break the current by operating the
packet or with a sterile bandage. switch before touching the injured person.

CARBON MONOXIDE POISONING (CO) If this is not possible, bear in mind that any other
attempt is highly dangerous also for the person
Carbon monoxide contained in engine exhaust gases assisting; therefore, any attempt to help the victim
is odorless and dangerous because it is poisonous and must be carried out without fail using means that are
with air, it forms an explosive mixture. insulating.

Carbon monoxide is very dangerous in enclosed WOUNDS AND FRACTURES

premises because it can reach a critical concentration
in a short time. The wide range of possible injuries and the specific
nature of the help needed means that the medical
When attending a person suffering from CO services must be called.
poisoning in enclosed premises, ventilate the
premises immediately to reduce the gas If the person is bleeding, compress the wound
concentration. externally until help arrives.

When accessing the premises, the person providing In the case of fracture do not move the part of the
the aid must hold his breath, not light flames, turn on body affected by the fracture. When moving an
lights or activate electric bells or telephones so as to injured person permission from that person must be
avoid explosions. received until you can help him. Unless the injury is

Page 7 of 35
life threatening, move the injured person with Rotating Parts
extreme care and then only if strictly necessary.

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.
Jacket Water Heater Voltage
Heat Exchanger Maximum Working Pressure

Coolant Mixture Air Filter Installation

Lifting Point 2.0 INSTALLATION/OPERATION

2.1 TYPICAL INSTALLATION

A typical Fire Pump installation is shown in Figure

#6 & 6A.

1) Pump/Engine set
2) Main Pump Controller
Automatic Start 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 Discharge Duct from Radiator

Page 8 of 35
 2.2.2 Extended Storage Maintenance Procedure

After a one year storage period or if the engine is

being taken out of service for more than 6 months,
additional preservation service must be performed as
follows:

1) Drain the engine oil and change the oil filter.

2) Refill the engine crankcase with MIL-L-
21260 preservative oil.
3) Change the fuel filter.
Figure #6
4) Install the coolant plugs and install coolant in
Typical Installation
the normal mix percentage of 50% coolant,
Heat Exchanger Cooled Engine
50% water, premixed.
5) Remove the protection from the intake and
exhaust openings.
6) Prepare a container as a fuel source using a
11 mixture of Mobilarma or Sta-Bil with ONLY
Diesel #2 fuel or “Red” diesel fuel (ASTM
D-975) or BS2869 Class A2. (Refer to
Section 3.1.1 for Fuel Specifications.)
7) Disconnect the coupling or drive shaft from
the pump.
8) Start and run the engine at a slow speed for
Figure #6A 1-2 minutes being careful not to exceed the
Typical Installation normal operating temperature.
Radiator Cooled Engine 9) Drain the oil and coolant.
10) Replace the protective plugs that were used
For radiator cooled engines, the total air supply path for shipping and storage.
to the pump room, which includes any louvers or 11) Attach to the engine a visible card, specifying
dampers, shall not restrict the flow of the air more “ENGINE WITHOUT OIL” DO NOT
than 0.2” (5.1mm) water column. Likewise, the air OPERATE”.
discharge path, which includes any louvers, dampers,
or ducting, shall not restrict the flow of air more than IMPORTANT: THIS TREATMENT MUST BE
0.3” (7.6mm) water column. REPEATED EVERY 6 MONTHS
************************
2.2 ENGINE STORAGE PUTTING ENGINE INTO SERVICE AFTER
ADDITIONAL PRESERVATION SERVICE:
2.2.1 Storage less than 1 year To restore the normal operation running conditions of
the engine, carry out the following:
Storing engines requires special attention. Clarke
engines, as prepared for shipment, may be stored for 1) Fill the engine sump with the normal
a minimum of one year. During this period, they recommended oil, to the required level.
should be stored indoors in a dry environment. 2) Remove the protective plugs used for
Protective coverings are recommended provided they shipping and storage.
are arranged to allow for air circulation. The stored 3) Refill cooling water to proper level.
engine should be inspected periodically for obvious 4) Remove the card “ENGINE WITHOUT OIL,
conditions such as standing water, part theft, excess DO NOT OPERATE”.
dirt buildup or any other condition that may be 5) Follow all steps of the Installation
detrimental to the engine or components. Instructions when the engine will be put into
Any such conditions found must be corrected service.
immediately.

Page 9 of 35
2.3 INSTALLATION INSTRUCTIONS coolants meeting ASTM-D6210
specifications for heavy-duty diesel engines.
The correct installation of the engine is very Never use light-duty or automotive coolants
important to achieving optimum performance and in the engine that are stated as ASTM-D3306
extended engine life. In this respect, the engine has only. Refer to Figure #22 in section 3.4.4
certain installation requirements, which are critical to for cooling system capacity. Refer to section
how it performs. These requirements are generally 3.4.5 for filling procedure.
associated with the cooling, exhaust, induction air, 5) Engine is shipped with oil installed. For
and fuel systems. make-up oil specifications refer to section
3.3 Lubrication System.
This section of the manual should be read in 6) Connect fuel supply and return line to fuel
conjunction with the relevant Installation and supply tank plumbing. Reference the Fuel
Operation Data Sheets. If there is any doubt about an System section of the Installation and
installation, contact should be made with Clarke Operation Data (see Page 5), for piping size,
Customer Support giving exact details of the maximum allowable fuel pump suction, and
problem. maximum allowable fuel head requirements.
Fill supply tank with ONLY #2 diesel fuel
All installations should be clean, free of any debris (ASTM D-975) or BS 2869 Class A2 “Red”
and dry. Care should be taken to ensure that there is diesel fuel, bleed supply system of air and
easy access to the engine for maintenance and repair. check for leaks. CAUTION: All diesel fire
The safety of personnel who may be in the area of the pump drivers manufactured by Clarke are
engine when it is running is of paramount importance designed and tested for use with only No.
when designing the installation layout. 2-D diesel fuel conforming to ASTM D-
975. Additionally, in European countries
1) Secure pump set to foundation and complete
installation in accordance with pump
an acceptable alternative fuel is “red”
diesel fuel conforming to BS2869 Class A2.
manufacturer’s instructions. Perform engine-
Both of these fuel specifications must
to-pump coupling alignment. Lubricate Falk
contain NO (0%) bio-fuel. Fuel supply level
coupling with supplied grease or driveshaft
must meet applicable code requirements. Do
universal joints with NLGI grade #1 or #2
not use a copper based or galvanized material
grease at the (3) Zerk fittings. (Refer to
for any component of a diesel fuel system.
section 2.4 for specific alignment
The fuel will chemically react with the zinc
instructions).
resulting in clogged fuel filters and injector
2) Install the heat exchanger discharge pipe.
systems.
The discharge pipe should be no smaller than
7) Remove protective covering on air cleaner
the outlet connection on the heat exchanger.
element.
Discharge water piping should be installed in
8) Connect jacket water heater (if supplied) to
accordance with applicable codes. All
AC power source. For KA4H series engines
plumbing connecting to the heat exchanger
the electrical supply requirements are
must be secured to minimize movement by
indicated on the electrical junction box.
the engine. Cooling loop water pressure to
Connect to the heater directly in the junction
the heat exchanger must not exceed the limit
box at the end of the heater only. Supply
that is stated on the heat exchanger supplied
wiring should never be routed through the
with the engine.
engine gauge panel. Severe damage to
3) Install all engine cooling system draincocks
critical engine control components could
and plugs.
result. Energize heater only after step #4 is
completed.
Engine 9) Connect exhaust system to flexible
Qty Description Location
Model connection on the engine. The exhaust
1/8” Water Heater system plumbing must be supported by the
1 KA4H
Draincock inlet tube building structure and not the engine. The
exhaust flexible connection is provided only
4) Fill engine cooling system with premixed for the purpose of thermal expansion and
50% water / 50% coolant solution. Use only
Page 10 of 35
 vibration isolation, not for misalignment or Before removing the driveshaft guard, disconnect the
directional change. negative battery cable from both batteries.
10) Make electrical DC connections between the Before beginning the alignment checks and making
engine gauge panel terminal strip (if any necessary corrections, install the driveshaft and
supplied) and the controller per the controller re-torque all driveshaft connection bolts to the values
manufacturer’s instructions. Refer to the given in the following table:
wiring diagram sticker located on the inside
cover of the engine gauge panel for proper BOLT TIGHTENING
connection of the water solenoid. DRIVE SIZE/ TORQUE
MODELS SHAFT MATERIA ft-lbs
11) Fill batteries with electrolyte per battery L GRADE (N-m)
manufacturer’s instructions. Connect cables
CDS10-SC 7/16-20
between engine and batteries only after KA4H SC41 Grade 8
50 - 55
electrolyte is installed. Refer to the wiring (68 – 75)
SC41A (Hi-Tensile)
diagram in engine documents or appropriate
wiring diagram (see Page 5), for correct
Note 1 – It is recommended that a medium strength
positive and negative connections.
threadlocker (Loctite 243–blue) be used in the
12) Connect negative cables directly to the brass
assembly and torquing of all hardware. This may be
ground bolt, as indicated with tag C133445.
purchased as part number C126758, 50ml bottle.
Connect each positive cable to the large outer
post of the manual starting contactors as
The following steps describe the proper way to check
indicated with tag C133443.
alignment. A small pocket scale or ruler with
13) Always follow fire pump controller operating
millimeter markings is recommended to make all
instructions when switching on/off battery
measurements.
chargers and disconnecting/reconnecting
A) To check the Horizontal Parallel Offset, the
batteries from engine.
driveshaft must be in the proper orientation.
14) Note: Clarke Operation and Maintenance
1. Rotate the shaft so the reference “AB” on the
Instructions Manual and other documentation
flywheel adapter disc or the circumference of
is located in a red bag attached to the engine.
the drive shaft flange (against the flywheel
15) IMPORTANT! In order to obtain prompt
adapter disc) is in the 12 o’clock position
Warranty Service and to comply with
shown on figure #7a.
Emissions Regulations, this engine must be
2. Measure from the face of the flywheel
registered to the final installation name and
adapter disc to point E. (Point E is on the
address. To register this engine, go to
bearing bore as shown in Figure #7a). This
www.clarkefire.com and select Warranty
measurement must be:
Registration.
Measurement Driveshaft
58 ± 1 mm. CDS10-SC / SC41 / SC41A
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

crankshaft centerlines for proper Parallel Offset and
Angular tolerance, the driveshaft must be installed
between the flywheel drive disc and the flanged hub
Figure #7a
on the pump shaft.
B) With the driveshaft in the same orientation as the
previous step (Step A), check the Horizontal
Angular alignment of the shafts.
Page 11 of 35
 1. Measure from the mating surface of the 1. Measure from the mating surface of the
companion hub to point G shown on figure pump companion hub of the drive shaft to
#7b. (Point G is the furthermost point on the point J as shown in figure #7d. (Point J is the
bearing bore). This measurement must be same as point G, with the driveshaft rotated
equal to the measurement at point E + 0.5 90o). This measurement must be equal to the
mm. 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 Figure#7d

driveshaft must be re-orientated.
1. Rotate the shaft 90○ so the reference “CD” on DRIVESHAFT MAINTENANCE
the flywheel adapter disc or the
circumference of the drive shaft flange 1. To service the driveshaft disconnect the
(against the flywheel) is in the position negative battery cables, remove the top of
shown on Figure#7c. guard and set aside.
2. Measure from the face of the flywheel 2. Rotate engine shaft manually so the u-joint
adapter disc to point H. (Point H is the grease fittings are accessible.
furthermost point on the bearing bore 3. Using a hand held grease gun with N.L.G.I.
diameter). The measurement must be: grade 1 or 2 grease position on grease fitting.
Measurement Driveshaft Pump with grease until grease is visible at all
60 ± 1 mm. CDS10-SC / SC41 / SC41A four cap seals.
4. Verify all driveshaft connecting bolts remain
tight. Re-torque per 2.4.1 if necessary.
5. Reinstall top of guard and connect negative
battery cables.

2.4.3 Other Coupling Types

Consult Factory or Clarke website at
www.clarkefire.com for additional
information.

2.5 WEEKLY TEST

It is recommended that the engine be tested weekly as

allowed by local jurisdictions. An experienced
Figure #7c operator should be present during the weekly test.

D) With the driveshaft in the same orientation as the Before starting the engine make sure of the
previous step (Step C), check the Vertical following:
alignment of the shafts.

Page 12 of 35
 1) The operator has free access to stop the Note: You can also start engines using manual
engine in an emergency. starting contactors.
2) The plant room ventilation ducts are open
and the engine has good access for air. IMPORTANT: Main pump controller selector
3) All the guards are in position and, if not, for should be in the OFF position when starting from
whatever reason, any rotating parts will be engine gauge panel. Be sure to return selector on
free and clear without restriction. main pump controller and engine gauge panel to
4) Battery covers are in place and there is AUTOMATIC after completing manual run.
nothing on top of or touching the engine,
which is not part of the original supply
specification.
5) Heat Exchanger Cooling: The water supply
for coolant is available again without
restriction.

When engine is running make sure that the coolant

temperature and oil pressure raw cooling water flow
are within the limits specified on the relevant
Installation & Operation Data Sheet (see Page 5).

If the coolant temperature is excessive, check:

a) Cooling loop strainers
b) Proper functioning of thermostat
c) Condition of heat exchanger tube bundle

2.6 STARTING/STOPPING THE ENGINE

2.6.1 To Start Engine:

Use main pump controller for starting. Follow

instructions provided by controller manufacturer.

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. For manual starting and stopping of an
engine with a gauge panel:
 Position MODE SELECTOR to MANUAL
RUN. (Refer to Figure #9).
 Lift and hold MANUAL CRANK #1, until
engine starts, or release after 15 seconds. If
unit fails to start, wait for 15 seconds, use
MANUAL CRANK #2 and repeat step.
 If COOLING WATER is not flowing or
engine TEMPERATURE is too HIGH,
open cooling system manual by-pass valves
(applies to heat exchanger cooled engines
only).

Page 13 of 35
 Front Opening Instrument Panel

5 2
1
1

6
11

7 4

8 9 9 10
Figure #9

1 – Emergency Operating Instructions 7 – Overspeed Indication Light

2 – Automatic-Manual Mode Selector 8 – Oil Pressure Gauge
3 – Manual Crank Controls 9 – Voltmeters Battery 1 & 2
4 – Overspeed Reset 10 – Coolant Temperature Gauge
5 – Manual Mode Warning Light 11 – Tachometer/Hourmeter
6 – Overspeed Verification

2.6.2 To Stop Engine stop lever to choke off fuel supply and shut the
engine down.
If engine is started from main pump controller use
main pump controller to stop the engine. The emergency stop lever is attached to the governor
If engine is started from engine gauge panel: on the front right side of the engine. To stop the
 Return MODE SELECTOR switch to engine, pull the emergency stop lever until it stops
AUTOMATIC/MANUAL STOP position, (see Figure #10). Continue to hold lever in “STOP”
engine will stop. position until engine comes to a complete stop.
 Close cooling system manual by-pass valve
if opened.

IMPORTANT: DO NOT leave the MODE

SELECTOR switch in the MANUAL RUN position
during AUTOMATIC operation. (The controller
will be unable to stop the engine and DAMAGE
MAY RESULT).

2.6.3 Emergency Stop Instructions

If energized to stop solenoid fails, you will NOT be Figure #10

able to stop the engine from the instrument control
panel or fire pump controller. Use the emergency

Page 14 of 35
3.0 ENGINE SYSTEMS 8.3.4.2* If diesel fuel is found to be deficient
in the testing required in 8.3.4.1.1, the fuel
3.1 FUEL SYSTEM shall be reconditioned or replaced, the
supply tank shall be cleaned internally, and
3.1.1 Diesel Fuel Specification the engine fuel filter(s) shall be changed.

All diesel fire pump drivers manufactured by Clarke 8.3.4.2.1 After the restoration of the fuel and
are designed, tested and warranted for use only with tank in 8.3.4.2, the fuel shall be retested each
No. 2-D Diesel Fuel conforming to ASTM 6 months until experience indicates the fuel
International D-975-11b or British Standard can be stored for a minimum of one year
BS2869:2010+A1:2011 Fuels oils for agricultural, without degradation beyond that allowed in
domestic and industrial engines and boilers - 8.3.4.1.1
Specification.
8.3.4.3 When provided, active fuel
Although the above referenced fuel specifications maintenance systems shall be listed for fire
allow limited amounts of Biodiesel, 100% petroleum pump service.
fuel is preferred and should be used whenever
possible. Biodiesel in any amount greater than that 8.3.4.3.1 Maintenance of active fuel
allowed by the above referenced specifications maintenance systems shall be in accordance
should not be used. The use of fuels not referenced with the manufacturer’s recommendations.
above, or Biodiesel in amounts greater than allowed
in the above referenced specifications, may affect 8.3.4.3.2 Maintenance of active fuel
performance and reliability, and may result in a non- maintenance systems shall be performed at a
warrantable engine condition. minimum annual frequency for any portion of
the system that the manufacturer does not
To insure engine reliability and performance, the fuel provide a recommended maintenance
provided for Clarke fire pump drivers must be frequency.
maintained in a quality condition. Refer to NFPA 25
2014, reprint provided below, for guidance to the 8.3.4.3.3 Fuel additives shall be used and
minimum requirements for fuel maintenance for all maintained in accordance with the active fuel
Clarke fire pump engine installations. maintenance system manufacturer’s
recommendations.
The following is reprinted from the “NFPA 25 2014
Standard for the Inspection, Testing, and A.8.3.4.1.1 Commercial distillate fuel oils
maintenance of Water-Based Fire Protection used in modern diesel engines are subject to
Systems,” Copyright © 2013 National Fire various detrimental effects from storage. The
Protection Association®. All Rights Reserved. origin of the crude oil, refinement processing
techniques, time of year, and geographical
8.3.4 Diesel Fuel Testing and Maintenance consumption location all influence the
determination of fuel blend formulas.
8.3.4.1 Diesel fuel shall be tested for Naturally occurring gums, waxes, soluble
degradation no less than annually. metallic soaps, water, dirt, blends and
temperature all contribute to the degradation
8.3.4.1.1* Fuel degradation testing shall of the fuel as it is handled and stored. These
comply with ASTM D975-11b Standard effects begin at the time of fuel refinement
Specification for Diesel Fuel Oils, or ASTM and continue until consumption. Proper
D6751 -11b Standard Specification for maintenance of stored distillate fuel is
Biodiesel Fuel Blend Stock (B100) for critical for engine operation, efficiency, and
Middle Distillate Fuels as approved by the longevity.
engine manufacturer, using ASTM D 7462 -
11 Standard Test Method for Oxidation Storage tanks should be kept water-free.
Stability of Biodiesel (B100) and Blends of Water contributes to steel tank corrosion and
Biodiesel with Middle Distillate Petroleum the development of microbiological growth
Fuel (Accelerated Method). where fuel and water interface. This and the
Page 15 of 35
 metals of the system provide elements that Instructions
react with fuel to form certain gels or
organic acids, resulting in clogging of filters 1) Loosen the air bleed vent screw on fuel
and system corrosion. Scheduled fuel injection pump.
maintenance helps to reduce fuel
degradation. Fuel maintenance filtration can
remove contaminants and water and
maintain fuel conditions to provide reliability
and efficiency for standby fire pump engines.
Fuel maintenance and testing should begin
the day of installation and first fill.
A.8.3.4.2 Where environmental or fuel
quality conditions result in degradation of
the fuel while stored in the supply tank, from
items such as water, micro-organisms and
particulates, or destabilization, active fuel Figure #12
maintenance systems permanently installed
on the fuel storage tanks have proven to be 2) Use fuel priming switch in instrument panel
successful at maintaining fuel quality. An to energize fuel transfer pump.
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
reconditioning.

3.1.2 Bleeding the Fuel System

CAUTION: Escaping fluid under pressure can

penetrate the skin causing series injury. Relieve
pressure before disconnecting fuel or other lines. Figure #13
Tighten all connections before applying pressure.
Keep hands and body away from pinholes and 3) After air is vented tighten bleed plug
nozzles, which eject fluids under high pressure. securely.
Use a piece of cardboard or paper to search for
4) Start engine and check for leaks.
leaks. Do not use your hand.
3.1.3 Changing the Fuel Filter Cartridges
If ANY fluid is injected into the skin, it must be B
surgically removed within a few hours by a doctor
Changing the cartridges and bleed any air from the
familiar with this type injury or gangrene may
fuel system as per instructions given in section 3.1.1.
result. Ref figure #11
Fuel filter changes should take place as per
recommendations and only using approved filters. It
may also be necessary to change filters out with the
recommendations in the event of:

1) The engine has had an overhaul.

2) The quality of the fuel is questionable.
3) The engine has been subjected to temporary
adverse conditions out of its normal
Figure #11
operating parameters.
Whenever the fuel system has been opened up for 4) The fuel tank condensation trap has not been
service (lines disconnected or filters removed), it will drained in line with manufacturer’s
be necessary to bleed air from the system. recommendations.

Page 16 of 35
Instructions 3.1.4 Fuel Tanks

1. Close fuel shut-off valve, if equipped. Keep the fuel tank filled to reduce condensation to a
2. Thoroughly clean primary fuel filter minimum. Open drain at the bottom of the fuel tank
assembly and surrounded area. See Figure once a week to drain off any possible water and/or
14a sediment. Fill tank after each test run.
3. Unscrew filter from filter head. Note: Per NFPA 25 standards, the fuel tank level
4. Install new filter element. must never be less than 67% of its capacity.
5. Thoroughly clean fuel pump pre-filter
assembly and surrounded area. Found under Maximum Allowable Fuel Head above Fuel pump,
flywheel housing. See Figure 14b Supply or Return.
6. Remove hose from filter inlet.
7. Unscrew filter from pump. Engine model feet meters
8. Install new filter. Threads are NPT so use KA4H 16.4 5
PTFE tape and pipe sealant as required.
9. Open fuel shut-off valve and bleed the fuel
3.1.5 KA4H Fuel Injection Pump Components
system (See 3.1.2). Tighten bleed plug.
10. Check for leaks
The KA4H series engines are configured for 12V
ETS. For injection pump information please consult
factory.

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.

Figure #14a 3.2.2 Ventilation

The engine must be provided with adequate

ventilation to satisfy the requirements of the
combustion system and allow adequate dissipation of
radiated heat and crankcase emissions. For all this
data refer to Installation & Operation Data (see Page
6). This data can be used for proper sizing of inlet
and outlet louvers.

3.2.3 Standard Air Cleaner

Air filter
Base engine Speed
restriction
All KA4H All 4

The standard air cleaner is a reusable type. Should a

situation occur where the air cleaner becomes
plugged with dirt (starving the engine of air), loss of
Figure #14b

Page 17 of 35
power and heavy black smoke will result; the air
cleaner should be serviced immediately.

CAUTION: Do not attempt to remove the air

cleaner while an engine is running nor run the engine
while the air cleaner is off. Exposed components
could cause severe injury to personnel and major
internal engine damage could occur should any
foreign matter be drawn into the engine.
NOTE: Do not attempt this while engine is running
NOTE: Do not over oil the reusable element
Figure #15

3.2.4 Crankcase Ventilation

Vapors which may form within the engine are

removed from the crankcase and gear train
compartment to the intake manifold by a continuous,
pressurized ventilation system.

A slight pressure is maintained within the engine

crankcase compartment. Vapors are expelled through
a vent pipe attached to the rocker cover breather
element. Ref. Figure #16

Figure #16

3.2.5 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. Refer
to Installation & Operating Data (see Page 6) for
exhaust data. Also refer to table below for maximum
exhaust restriction.

Exhaust
backpressure
Base engine Speed
limit
(in H20)
All KA4H All 35

Page 18 of 35
The installation of the exhaust system should consist 4) Return the unit back into service by returning
of the following: the AEC selector to “automatic” position and
 Personnel protection from hot surfaces. the manual operating lever to manual stop
 Adequate supports to prevent strain on the position.
engine exhaust outlet and minimize 5) Dispose used oil properly.
vibration.
 Protection against entry of water and other 3.3.3 Changing Oil Filter Cartridge
foreign matter.
1. Turn engine off.
While the engine is running inspect exhaust pipe 2. Put a tray under the filter to retain spilt
outlet outside of the pump room itself for lubricating oil.
environmental hazards such as excessive smoke 3. Remove the filter with a strap wrench or
conditions. The following could be used as a guide similar tool. Then dispose of the filter
for general engine operating conditions. properly

1) Blue Smoke – Possible engine oil

consumption.

2) White Smoke – Possibility of water in

cylinders, water in fuel or internal engine
problem.

3.3 LUBRICATION SYSTEM

3.3.1 Checking Sump Oil

Figure #18
Check the sump oil level using the dipstick on the
engine as shown in Figure #17 4. Clean the filter head.
5. Add a small amount of clean engine
This level must always be between the dipstick marks lubricating oil to the new filter. Allow the oil
Min. and Max. with the engine not running. enough time to pass through the filter
element.
6. Lubricate the top of the filter seal with clean
engine lubricating oil.
7. Fit the new filter and tighten it by hand only.
Do not use a strap wrench.
8. Ensure that there is lubricating oil in the
sump.
9. Operate the engine and check for leakage
from the filter. When the engine has cooled,
check the oil level on the dipstick and put
Figure #17 more oil into the sump, if necessary.
10. Return the unit back into service by returning
3.3.2 Changing Engine Oil the main pump controller selector to
“automatic” position and the manual
1) Operate the engine until it is warm. operating lever to AUTO-OFF position.
2) Stop the engine. Remove the sump drain
plug and drain the lubricating oil from the 3.3.4 Oil Specification
sump. Fit the drain plug tighten the plug to
34 Nm (25lbf-ft) / 3.5 kgf-m. Important: Do not add makeup oil until the oil
3) Fill the engine with oil to the ‘FULL” mark level is BELOW the add mark on the dipstick.
on the dipstick with new and clean
lubricating oil of an approved grade.
Page 19 of 35
Oil spec to be used for all engine models:  Be compatible with engine hose and seal
API Symbol: materials.
 Provide adequate freeze and boil over
protection.

WARNING
A water and anti-freeze solution is required for
pump installations. Premixing this solution prior
to installing is required. This prevents possible
pure anti-freeze chemical reactions to block
Note: CF-4, CG-4, CH-4 and CI-4 are also acceptable heater elements which can burnout the element.
Figure #19 Please see the I&O section (see Page 6) for proper
cooling system capacities of each model.
SAE Viscosity Grade: 10W-40
Note: ACEA-E4 or ACEA-E5 are also acceptable. 3.4.3 Water

3.3.5 Oil Capacities (Including Filter) Water can produce a corrosive environment in the
cooling system, and the mineral content may permit
scale deposits to form on internal cooling surfaces.
ENGINE OIL CAPACITY
Therefore, inhibitors must be added to control
MODEL QUARTS (LITERS)
corrosion, cavitation, and scale deposits.
KA4H – All Models 11.6 (11)
Figure #20 Chlorides, sulfates, magnesium and calcium are
among the materials which make up dissolved solids
3.4 COOLING SYSTEM that may cause scale deposits, sludge deposits,
corrosion or a combination of these. Chlorides
3.4.1 Intended Engine Operating Temperature and/or sulfates tend to accelerate corrosion, while
hardness (percentage of magnesium and calcium salts
The KA4H engines are provided with a heat broadly classified as carbonates) causes deposits of
exchanger to maintain the engine coolant temperature scale. Water within the limits specified in figure #21
within recommended operating guidelines. is satisfactory as an engine coolant when properly
inhibited. Use of distilled water is preferred.
The KA4H engines have an intended engine
operating temperature of 160º F (71ºC) to 185º F (85º Grains
C). A high coolant temperature switch is provided to Parts per per
indicate a high coolant temperature alarm at 205º F Materials Million Gallon
(96º C). Chloride (Max.) 40 2.5
3.4.2 Engine Coolant Sulfates (Max.) 100 5.8
Total Dissolves Solids
The following information is provided as a guide for 340 20
(Max.)
Clarke Engine users in the selection of a suitable
coolant. Total Hardness (Max.) 170 10
Figure #21
The water/ethylene glycol/inhibitor coolant mixture
used in Clarke engines must meet the following basic 3.4.4 Coolant Capacities
requirements:
 Provide for adequate heat transfer. Ethylene Glycol or Propylene Glycol are acceptable:
 Provide protection from cavitation damage.
 Provide a corrosion/erosion-resistant IMPORTANT:
environment within the cooling system. Do not use cooling system sealing additives or
 Prevent formation of scale or sludge deposits antifreeze that contains sealing additives.
in the cooling system.

Page 20 of 35
Do not mix ethylene glycol and propylene glycol coolant as required to maintain original strength
base coolants. levels. Refer Figure #23 for proper concentrations of
inhibitors.
Do not use coolants that contain nitrites. Min. Max
PPM PPM
Use an ethylene glycol coolant (low silicate Boron (B) 1000 1500
formulation) that meets the standard of either the GM Nitrite (NO )2
800 2400
6038-N formulation (GM1899-M performance) or 3
ASTM D-6210 requirements. Nitrates (NO ) 1000 2000
Silicon (Si) 50 250
A 50% coolant water solution is recommended. A Phosphorous (P) 300 500
concentration over 70% is not recommended because
PH 8.5 10.5
of poor heat transfer capability, adverse freeze
protection and possible silicate dropout. Figure #23
Concentrations below 30% offer little freeze, boil
over or corrosion protection. Do not use soluble oils or chromate inhibitors in
IMPORTANT Clarke engines. Detrimental effects will occur.
Never use automotive-type coolants (such as those To properly check inhibitor concentrations it may be
meeting only ASTM D3306 or ASTM D4656). necessary to contact your local Service/Dealer for
These coolants do not contain the correct additives assistance. Refer to Parts Information Section to
to protect heavy-duty diesel engines. They often obtain the part number for the factory Coolant
contain a high concentration of silicates and may Analysis Kit. This kit can be purchased for a
damage the engine or cooling system. nominal fee for analyzing the conditions of the
ENGINE COOLANT CAPACITY engine’s coolant.
MODEL QUARTS (LITERS)
All KA4H Models 10 (9.5) 3.4.6 Procedure for Filling Engine
Figure #22
During filling of the cooling system, air pockets may
form. The system must be purged of air prior to
3.4.5 Coolant Inhibitor
being put in service. This is best accomplished by
filling with a pre-mix solution.
The importance of a properly inhibited coolant Caution: Do not overfill cooling system.
cannot be over-emphasized. A coolant which has A pressurized system needs space for heat
insufficient or no inhibitors at all, invites the expansion without overflowing.
formation of rust, scale, sludge and mineral deposits.
These deposits can greatly reduce the cooling Remove pressure cap from expansion tank and fill
systems efficiency and protection capabilities. the cooling system with a 50/50 coolant mixture to
cold line on expansion tank.
Recommended supplemental coolant inhibitors are a
combination of chemical compounds which provide
corrosion protection, cavitation suppression, pH
controls and prevents scale. These inhibitors are
available in various forms, such as liquid packages or
integral parts of anti-freeze.

It is imperative that supplemental inhibitors be added

to all Clarke engine systems. A pre-charge dosage
must be used at the initial fill and the maintenance
dosage used at each service interval. Serious damage
will occur unless inhibitors are used. Some of the
more common corrosion inhibitors are borates,
nitrates and silicates.
Inhibitors become depleted through normal
operation; additional inhibitors must be added to the

Page 21 of 35
 have a radiator cooled Clarke engine, you can
disregard this section. Heat exchanger cooled diesel
engine drivers require a clean source of pressurized
water from the discharge side of the fire pump in
order to keep the engine from overheating by
providing a specified minimum amount of raw water
flow.

3.4.7.2 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.
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
Figure #24 available at the engine outlet.
Note: Use a fill rate of no more than 10 liters/min (3 Figure #25 shows the standard NFPA 20 cooling
gpm). loop piping arrangement. The cooling loop consists
of an Automatic flow line with a 12v or 24v solenoid
Install the pressure cap, start and run engine for valve (HSC and ES pump applications only) that is
approximately 5 minutes in order to purge the air energized to open anytime the engine is called upon
from the engine cavities. to run from either the fire pump controller or from
the engine instrument panel.
When verifying that the coolant is at a safe operating
level, it is best to wait until the engine temperature NOTE: VT type pump applications do not require a
drops to approximately 120ºF (49ºC), or lower, solenoid valve in the Automatic flow line.
before removing the pressure cap. NOTE: With the Mechanical Engine and Alarm
Remove the pressure cap and refill to the proper fill Control Board, See section 3.5.5, the solenoid valve
level. To continue the deaeration process start and will open 15 seconds after engine shutdown and will
run engine until the temperature stabilizes at stay open for 60 seconds. This allows for raw water
approximately 160°-200° (71°-93° C) or run engine to flow through the heat exchanger and reduce the
for 25 minutes, whichever is longer. During this heat soak rise caused in the engine.
warming process, you may see coolant coming from
the overflow tube attached at the pressure cap The second flow line is called the Manual by-pass
location. Allow engine to cool, then remove the line and it can be opened at any time if for any reason
pressure cap and refill to the proper fill level. the engine shows signs of overheating. Each line has
two (quarter turn) shutoff values installed and the
Caution: Do not remove pressure cap while coolant normal position of the shutoff valve is to remain open
is at normal operating temperatures. Possible in the Automatic flow line and remain closed in the
personal injury could result from the expulsion of hot Manual by-pass flow line.
coolant.
NOTE: Opening up both lines to flow is never a
3.4.7 Providing adequate Raw Water Supply to the problem should there be some concern of engine
Engine Heat Exchanger overheat, especially if there is an emergency
situation. The Manual by-pass line can only be
3.4.7.1 Raw Water Supply opened by an operator in the pump room.

Most Clarke diesel engine fire pump drivers are heat The shutoff valves are all identified to show which
exchanger cooled and some engines also have a are Normally Open (Automatic flow line) and which
charge air cooler (CAC) that uses raw water to cool are Normally Closed (Manual by-pass flow line).
the air before entering the intake manifold. If you The shutoff valves are also used to isolate water
Page 22 of 35
pressure in the event of maintenance to pressure The pressure regulators are set to limit downstream
regulators, strainers and solenoid valve. Shut off pressure to 60 psi (4 bar). There is a 0-60 psi (0-4
valves in the Automatic flow line are provided with bar) pressure gauge installed at the cooling loop
lockable handles for cooling loops that have been outlet, and prior to the engine heat exchanger (or
tested to FM requirements. These valves have been CAC).
provided with a temporary locking pin to keep them
in the open position, see detail A in Figure #25. This Wye strainers are used to remove debris from the raw
temporary retainer needs to be replaced with a 9/32" water supply. One strainer is in the Automatic flow
lock. line and the other is in the Manual by-pass flow line.
In each flow line there is also a pressure regulator.
Each pressure regulator protects the downstream Note: See section 3.4.7.5 regarding strainer
piping from over-pressurization which includes the maintenance.
tube side of the engine shell & tube heat exchanger
(and/or CAC) and to control raw water flow rate.
  

 
Figure #25

3.4.7.3 Setting Raw Water Flow Rate most values are given based upon engine speed. You
will find this datasheet in the documentation bag that
The proper amount of raw water flow thru the engine is shipped with the engine for your specific Clarke
is of the utmost importance, and the pressure gauge model. This datasheet must be available during
value does little to indicate if there is sufficient flow. commissioning in order to set the proper minimum
When the engine is exercised weekly, the amount of raw water flow. With the fire pump flowing 150% of
raw water flow exiting the engine should always be rated flow, and the Automatic flow line open; verify
checked to verify it does not appear to have sufficient raw water flow rate is achieved and that the
diminished. reading of the cooling loop pressure gauge does not
exceed 60 psi (4 bar). You will need to capture the
During initial commissioning of the engine, it is flow for a specific amount of time coming out of the
important to correctly set the raw flow rate going thru heat exchanger and going to a floor drain in order to
the cooling loop. Each Clarke engine model has an establish a reasonably accurate flow rate value. Using
Installation and Operation (I&O) Datasheet that a container or bucket of known volume, record the
provides basic operating conditions of the engine and time required to fill the container and compare to the
Page 23 of 35
gpm or L/min value provided on the I&O datasheet. It can be not stressed enough how important it is to
THIS IS CRITICAL FOR PROPER ENGINE keep the wye strainers within the cooling loop clean:
COOLING AT MAXIMUM PUMP LOAD!! Most engine failures occur due to plugged cooling
If proper cooling water flow rate is established then loop strainers! If the raw water supply has debris in
no fire pump controller alarm will be triggered to it (leaves, stones, etc) as the strainer accumulates
indicate clogged raw water strainer (low raw water more debris (that will not pass thru it), the flowrate
flow). After verifying raw water flow rate in the will continue to diminish which will eventually starve
Automatic flow line, open the Manual by-pass line the engine of adequate cooling water flow which will
shut-off valves, and then close the Automatic flow lead to engine overheat and catastrophic engine
line shut-off valves and repeat the above process in failure. When this occurs you have no fire
order to verify the flowrate going thru the Manual by- protection! Clarke recommends that after the initial
pass line. Note, with Automatic flow line closed the engine commissioning and also prior to each weekly
controller low raw water flow alarm may be present, exercise of the engine / fire pump set, both strainers
this is normal. Once this is completed; close the be removed and cleaned and then re-installed before
Manual by-pass shut-off valves and open the starting the engine.
Automatic flowline shut-off valves to restore
conditions back to normal. Clarke engines are equipped with an alarm that is
meant to signal diminished raw water flow rate
3.4.7.4 Raw Water Outlet (terminal 311), possibly due to clogged raw water
strainers in the cooling loop. Refer to Figures 25 and
NOTE: NFPA 20 does allow for the heat exchanger 26 for location of sensors. A circuit board located
outlet flow to be returned to a suction reservoir. This near the front of the cooling loop monitors
makes it very difficult to measure the flowrate. differential pressure between the two sensors and will
When discharging to a suction reservoir, NFPA send an alarm to the controller if a low water flow
provides additional requirements: condition exists.
Additionally, a raw water temperature switch will
1) A visual flow indicator and temperature send an alarm (terminal 310) when temperature of the
indicator are installed in the discharge (waste water exceeds 105°F (41° C). Refer to Figures 26
outlet) piping. and 26A1 for location of switch. If either of these
2) When waste outlet piping is longer than 15ft alarms are active, it indicates that the cooling
(4.6m) and / or the outlet discharges are more system’s capability may be compromised.
than 4ft (1.2M) higher than the heat
exchanger, the pipe size increased by at least
one size.
3) Verify that when the correct flow rate is
achieved that the inlet pressure to the heat
exchanger (or CAC) does not exceed 60psi
(4bar)

If you have such an installation, it is recommended

that you run the engine for a period of time at fire
pump 150% flow and confirm the visual flow
indicator is showing water flow, the temperature rise
is not excessive (usually no more than 40F (4.5C)
over ambient raw water temperature) and the engine
is showing no signs of overheating.  
Figure #26
3.4.7.5 Raw Water Quality, Strainers and 3.4.7.6 Backflow Preventers
Deterioration of Heat Exchanger (or CAC)
NFPA20 allows for the use of backflow preventers in
Over time, as the heat exchanger (or CAC) begins to the Automatic and Manual flow line of the cooling
plug and foul, this pressure will rise and the flow will loop as required by local code. For specific
diminish which could mean that the heat exchanger application information contact factory.
(or CAC) may have to be replaced.
Page 24 of 35
3.4.7.7 Raw Water Outlet Temperature The engine coolant flows through the shell side of the
heat exchanger, engine coolant pump, engine block,
Certain local codes may not allow you to discharge cylinder head, jacket water heater, thermostat and
the waste water outlet from the engine heat expansion tank.
exchanger either due to its temperature or it now
being considered hazardous waste. It is On heat exchanger equipped engines raw cooling
recommended you always check local codes water flows through the tube side of the heat
regarding waste water discharge. exchanger.

3.4.8 Flow Paths of Engine Cooling System Refer to Figure #27

Figure 27

3.4.9 IMPORTANT SERVICE NOTICE 4) Run the engine to verify normal operating
temperature.
Any time an engine experiences a high coolant
temperature alarm condition the primary cause of the 3.4.9.1 Water Pump Cavitation
overheat must be determined and the cause corrected
to prevent a recurring overheat event.. Additionally, Cavitation is a condition that occurs when bubbles
if an event of a restricted flow, collapsed hose, form in the coolant flow in the low pressure areas of
insufficient coolant level or failed pressure cap is the cooling system and implode as they pass to the
experienced, further investigation of the cooling higher pressure areas of the system. This can result in
system is required. damage to cooling system components, particularly
the water pump impeller and cylinder liners.
1) The coolant shoud be drained (after de- Cavitation in an engine can be caused by:
energizing the coolant heater  Improper coolant
2) Replace the engine thermostat(s)  Restricted coolant flow caused by collapsed
3) Remove the engine water pump and hose or plugged system
inspect the impeller and seal for damage, replace as  Coolant fill cap is loose or unable to retain
necessary. Reassemble and refill coolant according the required pressure
to the Installation and Operations Instruction Manual.  Insufficient fluid level
Page 25 of 35
  Failure to de-aerate
 Overheat A
3.5 ELECTRICAL SYSTEM

3.5.1 Wiring Diagrams (Only with Engine Gauge

Panel)

Run/Stop Drawing Description

Solenoid No. (DC Voltage)
UL/FM Front
Opening
ETS C072483 Instrument
Panel with
C071963
speed switch
ETS = Energized to Stop

Drawing No. Description

(AC Voltage) Figure #29
NFPA-20, UL/FM,
Engine Jacket Water To adjust Belt Tension:
C07651 Heater
(NL Models - 1) Check belt tension of each belt with
Optional) tension gauge. Tension should be
between 22.5-26lbs (100-115N)
Figure #28
2) If belt is not properly tensioned loosen
bolt at A and adjust tension.
3.5.2 Checking Drive Belt Tension and Adjustment
3) Re-tighten bolt at A
All drive belts must be adequately tightened to secure
3.5.3 Speed Switch (when supplied)
that both the engine water pump and battery charging
alternator are operating efficiently. Refer to Figure
Overspeed is defined as 110% of rated speed for
#29.
engines rated from 2800 through 3000 rpm. In the
B event of an engine overspeed, the speed switch
signals the main pump controller and also affects an
engine shutdown. A visual overspeed warning lamp
will illuminate on the Clarke panel (figure #30A).
The OVERSPEED RESET (figure# 9) 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 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 provide the main pump

Page 26 of 35
controller with an overspeed signal and engine connect circuit #312 as a means to alert the user
shutdown at 67% of the set overspeed RPM. outside of the engine room
Start the engine via the main pump controller; the Note: When first applying battery power to the
speed switch will generate an overspeed signal and engine, or after activating the overspeed reset switch,
shutdown protecting both the engine and pump. the OVERSPEED SHUTDOWN lamp and red LED
on the speed switch will flash several times. This is
EXAMPLE an “INITIALIZATION PATTERN” and is normal.
Rated Speed: 3000 RPM This will be referred to in the following
Overspeed Shutdown: 3300 RPM (110% of troubleshooting section.
3000 RPM)
Verification Shutdown: 2211 RPM (67% of
3000 RPM)

CAUTION-after verification of overspeed, lift the

OVERSPEED RESET switch and reset the main
pump controller to re-instate normal operation of the
engine and speed switch.

Refer to Engineering Technical Bulletin – ETB003,

part number C133407, on the www.clarkefire.com
website for adjusting the overspeed setting for range
rated engines. Figure #30A

3.5.4 Magnetic Pick-Up (when supplied)

A magnetic pick-up, mounted in the flywheel

housing, provides the input signal for the tachometer
overspeed switch, and/or the main pump controller.
There should be a 0.03" air gap between the top of
the ring gear and the center of the magnetic pick-up.
With one tooth centered in the magnetic pick-up hole,
thread the pickup in until it touches the gear tooth
and then back it out 1/2 turn. Tighten jam nut while
holding the pickup in position. Reconnect to wiring
harness.
Figure #30B
3.5.5 Mechanical Engine Control and Alarm Board
(MECAB) Speed Switch Troubleshooting
List of Troubleshooting Malfunctions
This engine is equipped with a speed switch Two (2) blinks – Electrical Current Exceeds 10
capable of sensing engine sensor malfunctions Amps on Alarm Circuits: Status lamps will flash
and/or electrical over-current(s) on engine two times continuously on the Clarke instrument
alarm circuits and alerting the user via flashing panel and a “Low Engine Coolant Temperature”
status lamps. This flashing status indication is alarm will be sent to the fire pump controller via
done so with the red “OVERSPEED circuit #312.
SHUTDOWN” lamp on the outside of the Clarke
instrument panel (Figure #30A) and a red LED Cause:
located on the middle of the speed switch inside
Electrical current exceeds 10 amps on one or more
of the Clarke instrument panel (Figure #30B).
engine / fire pump controller inter-connect circuits
In addition to these flashing status lamps, a
“Low Engine Coolant Temperature Alarm” is Engine run alarm (#2)
sent via engine / fire pump controller inter- Engine overspeed alarm (#3)

Page 27 of 35
 Engine low oil pressure alarm (#4)
Engine high coolant temperature alarm (#5)
Engine low coolant temperature alarm (#312)

Corrective actions:

Check each of the above circuits to determine which

contains the current overload.
Once circuit(s) overload are corrected: On the Clarke
instrument panel, operate the “OVERSPEED
RESET” switch for two (2) seconds and release
Figure #31
(Figure #30C).
On the Clarke instrument panel, operate the
“OVERSPEED RESET” switch for two (2) seconds
and release. (Refer to Figure #30C).

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

temperature thermistor.
Figure #30C
Five (5) blinks on instrument panel – Oil pressure
The “INITIALIZATION PATTERN will flash. This is switch or Engine speed sensor (magnetic pick-up)
normal. The continuous two (2) blink flash sequence malfunction: Status lamps will flash five times
should turn off at this point. continuously on the Clarke instrument panel and a
“Low Engine Coolant Temperature” alarm will be
Three (3) blinks – Engine Coolant Temperature sent to the fire pump controller via circuit #312.
Sensor malfunction: Status lamps will flash three
times continuously on the Clarke instrument panel Cause:
and a “Low Engine Coolant Temperature” alarm will Oil pressure switch failure or magnetic pick-up
be sent to the fire pump controller via circuit #312. failure.

Cause: Corrective Actions:

Engine coolant temperature sensor circuit is open or Oil Pressure switch check
closed Verify wiring and connector at engine oil pressure
Corrective Actions: switch are secure. Pressure switch is located on left
side of engine.
Verify wiring and connector plug at engine coolant
temperature sensor are secure. Sensor is located in
coolant manifold block at the front of the engine.

Figure #32

Page 28 of 35
With engine off, check continuity between the WK sequence should turn off at this point. If problem still
terminal and engine ground. Note, do not disconnect exists, replace engine speed sensor (magnetic pick-
wire when performing this task.. up), Clarke part number C071883.

If circuit is open, replace oil pressure switch/sender, 3.5.6 FIELD SIMULATION OF PUMP
Clarke part number C071884. CONTROLLER ALARMS

After new switch is replaced: On the Clarke Field simulation of (6) pump controller alarms
instrument panel, operate the “OVERSPEED
RESET” switch for two (2) seconds and release. • Alarm 1: Over speed Shutdown: Follow
(Refer to Figure #30C) over speed verification steps per section 3.5.3.

The “INITIALIZATION PATTERN will flash. This is • Alarm 2: Low Oil Pressure: With the engine
normal. The continuous five (5) blink flash sequence running, , jumper the “WK” terminal on the oil
should turn off at this point. pressure switch/sender to engine ground .

If circuit is closed, the oil pressure switch is not Continue jumping the circuit until the alarm is
damaged and is working normally as expected. indicated at the controller.
Proceed to engine speed sensor check, below.
Engine speed sensor (magnetic pick-up) check • Alarm 3: High Engine Coolant Temperature:
Verify wiring and connector at engine speed sensor With the engine running, set the High Engine Coolant
are secure. Magnetic pick-up is located on the Temperature DIP switch to “ON” (see Figure #34).
flywheel housing. Use a fine pick or small screwdriver and slide the
white slider to the left. Wait for 30 seconds and
controller alarm will activate. Set white DIP switch
slider to “OFF” (right) when simulation is complete.

• Alarm 4: Low Engine Coolant Temperature: With

the engine not running, set the Low Engine Coolant
Temperature DIP switch to “ON” (see Figure #34).
Use a fine pick or small screwdriver and slide the
white slider to the right. Controller alarm will
activate immediately. Set white DIP switch slider to
“OFF” (left) when simulation is complete.

Low Coolant Temperature

Simulation switch
Figure #33
OFF ON

With engine running, verify that the tachometer is

ON OFF
functioning normally.
High Coolant Temperature
Refer to section 3.5.4 of Engine Operator’s Manual Simulation switch
to properly reposition the magnetic pick-up if Figure #34
tachometer is not functioning.
• Alarm 5: Overcrank: NEVER shut off the fuel
Once magnetic pick-up is repositioned: On the supply to the engine to prevent it from
Clarke instrument panel, operate the “OVERSPEED starting. Shutting off the fuel supply will
RESET” switch for two (2) seconds and release. cause an air lock condition in the fuel system
(Refer to Figure #30C). and possibly cause fuel system component
damage.
“OVERSPEED SHUTDOWN” lamp will flash a
sequence of one (1) blink, then four (4) blinks. This This engine has an ETS Governor Solenoid: Use
is normal. The continuous five (5) blink flash manual stop override to prevent the engine from
Page 29 of 35
starting during the cycle-crank testing. Override must If the engine has been designed and tested for range
be held continuously each time the engine attempts a rating, stamp the metal tag titled “FIELD SETTING”
crank start. This will allow the engine to crank only with the final adjusted speed, horsepower, and
but will prevent it from running. overspeed shutdown setting and keep with the
engine. Refer to Figure #36.
• Alarm 6: Low Fuel Pressure: With the engine
running from the main pump controller, jumper
between the terminals of the fuel pressure switch.
Alarm will be indicated at interconnect terminal #302

3.5.7 BATTERY REQUIREMENTS

Figure #36
All Clarke engine models require 8D batteries, as
sized per SAE J537 and NFPA20. The battery 4.0 MAINTENANCE SCHEDULE
should meet the following criteria:
Cold Cranking Amps (CCA @ 0°F): 1400 4.1 ROUTINE MAINTENANCE
Reserve Capacity (minutes): 430
Refer to Clarke drawing C131885 (see Page 5) for
NOTE: The following Routine Maintenance schedule
additional information on Clarke supplied batteries.
is based on an engine usage rate not exceeding 2
hours per month. For UL/FM engine models, also
3.6 ENGINE SPEED ADJUSTMENT
refer to NFPA25.
LEGEND:
A mechanical governor controls the engine speed.
 Check
The governor is built into the fuel injection pump. All
 Clean
governors are adjusted to the rated speed at
 Replace
nameplate power or maximum allowed pump load
o Lubricate
before leaving Clarke. During Start-Up Inspection or
WEEKLY
when placing reconditioned units into service, some
 Air Cleaner
minor speed adjustment may be required. It is
 Battery
recommended that this adjustment be performed by
 Belts
the authorized Service Dealer representative.
 Coolant Hoses
 Coolant Leaks
To adjust the speed of the engine:
 Coolant Levels and Condition
 Cooling Loop Valves Position
A. Start the engine by following the “To Start
 Cooling Water Solenoid Valve
Engine” Procedure in this manual.
 Cooling Water Discharge
B. Let the engine warm-up. Loosen the jam
 Exhaust System
nut(s) (Figure #35).
 Fuel Tank
C. While observing the instrument panel
 General Inspection
tachometer rotate the long adjustor clockwise
 Governor Run-Stop Control
to lower the RPM and counter clockwise to
 Jacket Water Heater
raise the RPM’s until desired speed is
 Lubrication Oil Level
obtained.
 Operating Gauges
D. Holding secure the long adjustor with a
 Remove Water from Fuel Filter
wrench tighten the jam nut.
 Run Engine
E. Stop engine by following “To Stop Engine”
 Warning Light
Procedure in this manual.
 Cooling Water Strainers
EVERY 6 MONTHS
 Batteries
 Battery Charging Alternator
 Belt tension
 Coolant Protection Level
Figure #35  Driveshaft U-Joints

Page 30 of 35
  Fuel Lines  Part Number(s) Refer to Engine Maintenance
EVERY 1 YEAR Parts List section 6.2 or Parts Illustration (see
 Air Cleaner Page 5).
 Coolant Inhibitor Contact numbers for spare parts:
 Crankcase Vent System • www.clarkefire.com
o Driveshaft U-Joints • Phone USA: (513) 771-2200 Ext. 427 (calling
 Fuel & Oil Filters within USA)
 Heat Exchanger Electrode • Phone UK: (44) 1236 429946 (calling outside USA)
 Lubricating Oil • Fax USA: (513) 771-5375 (calling within USA)
 Mounting Isolators • Fax UK: (44) 1236 427274 (calling outside USA)
 Wiring System • E-Mail USA: parts@clarkefire.com
EVERY 2 YEARS • E-Mail UK: dmurray@clarkefire.com
 Air Cleaner
 Batteries 6.2 ENGINE MAINTENANCE PARTS LIST
 Belts
 Coolant Hoses Refer to Appendix “A“ at the end of this manual.
 Coolant Air Filter
 Thermostat Engine Model Service Kit Air Filter Oil
 Remove Water Pump to Inspect Impeller and KA4H 99-55050 C121157
Seal Figure #37

IMPORTANT: Set main pump controller to “OFF” 7.0 OWNER ASSISTANCE

while servicing engine. Before turning the main
pump controller to the "OFF" position, check with Consult Clarke Service Dealer or Factory. Service
the maintenance and security supervisors to verify Dealers can be located by going to our website:
that all the departments concerned will be alerted of www.clarkefire.com.
the temporary interruption of their fire protection
equipment for normal maintenance or testing. Also, 8.0 WARRANTY
alert the local fire department in the event that the
main pump controller is connected by silent alarm to 8.1 GENERAL WARRANTY STATEMENT
headquarters. When servicing is complete, return
main pump controller selector to "Automatic" The satisfactory performance of Clarke engines and
position and the mode selector on the engine to the goodwill of owners / operators of Clarke engines
“Automatic” position. Advise the appropriate are of primary concern to the Engine Manufacturer,
personnel the engine has been returned to the the Engine Service Dealer and Clarke. All provide
“Automatic”. support of these products after final installation of the
complete fire pump and sprinkler system.
5.0 TROUBLE SHOOTING
Warranty responsibility involves both Clarke and the
Consult Clarke Service Dealer or Factory. Service Clarke service organizations worldwide.
dealers can be located by going to our website:
www.clarkefire.com The Engine Manufacturer (Clarke) provides
. Warranty for the basic engine components and on the
6.0 PARTS INFORMATION accessories added to meet the NFPA-20
specifications and FM/UL certification requirements.
6.1 SPARE PARTS
8.2 CLARKE WARRANTY
To ensure best operation and efficiency of all engine
components, always use genuine Clarke spare parts. All Clarke warranted components have warranty for a
duration of 24 months beginning at the Start-up date
Orders should specify: of the fire pump system. The warranty coverage
 Engine Model Number - See Engine General includes replacement of the part and reasonable cost
 Engine Serial Number - Specification of labor for installation. Components failed due to

Page 31 of 35
improper engine installation, transportation damage, NOR IS ANYONE AUTHORIZED TO MAKE
or misuse is not covered under this warranty. ANY ON CLARKE’S BEHALF. CLARKE
AND/OR THE SELLER SHALL NOT BE LIABLE
Clarke is not responsible for incidental or FOR SPECIAL, INDIRECT, INCIDENTAL, OR
consequential costs, damage or expenses which the CONSEQUENTIAL DAMAGES OF ANY KIND.
owner may incur as a result of a malfunction or
failure covered by this warranty. 8.3.2 TO OBTAIN WARRANTY SERVICE:

8.3 WARRANTY PERIOD OWNER'S WARRANTY RESPONSIBILITIES:

Clarke’s obligation under this warranty is expressly As the off-road engine owner, you are responsible for
limited, at its option, to an appropriate adjustment, the performance of the required maintenance listed in
repair or replacement of such part or parts as found to your owner's manual. Clarke recommends that you
be defective following an inspection by Clarke or an retain all receipts covering maintenance on your off-
authorized service facility designated by Clarke. road engine, but Clarke cannot deny warranty solely
for the lack of receipts or for your failure to ensure
8.3.1 EXCLUSIONS: the performance of all scheduled maintenance.

The following items are not covered by this warranty. As the off-road engine owner, you should however be
 Damage caused by: (i) an accident or aware that Clarke may deny you warranty coverage if
casualty; (ii) unreasonable use or neglect; your off-road engine or a part has failed due to abuse,
(iii) normal wear; (iv) premature wear from neglect, improper maintenance or unapproved
improper maintenance; (v) improper storage; modifications.
(vi) old or contaminated fuel left within the
fuel system, which includes but is not limited Your engine is designed to operate on diesel fuel
to tanks, fuel lines, or fuel injection only. Use of any other fuel may result in your engine
components. no longer operating in compliance with emissions
 Failures caused by: (i) faulty repairs made by requirements.
any party other than Clarke or an authorized
service facility designated by Clarke (ii) use If you have any questions regarding your warranty
of non- Clarke replacement service parts; or rights and responsibilities, you should contact
(iii) an act beyond the control of Clarke, Clarke by visiting www.Clarkefire.com.
which includes but is not limited to theft,
vandalism, fire, lightning, earthquake, 8.3.3 COVERAGE
windstorm, hail, volcanic eruption, flood or
tornado. Clarke will repair or replace emission control system
 Transportation charges in connection with parts, components and sub-assemblies found to be
the repair or replacement of defective parts. defective with respect to materials or workmanship at
 Engine accessories such as fuel tanks, no cost to you including engine exhaust system
clutches, transmissions, power drive related diagnosis, labor and parts. The choice and
assemblies, and batteries, unless supplied or responsibility of the decision to repair or replace an
installed by Clarke. emission control system defect will be solely that of
 Rental of equipment during performance of Clarke. Emission control system parts/ components
warranty repairs. covered by the Federal and California Emission
 Fuel, lubricating oil, air filters, oil filters, or Control Systems Limited Warranty are listed below.
coolant/antifreeze
• Fuel injector(s)
IMPLIED OR STATUTORY WARRANTIES, • Injection pump(s)
INCLUDING THOSE OF MERCHANTABILITY • Exhaust manifold
AND FITNESS FOR A PARTICULAR PURPOSE, • Intake manifold
ARE EXPRESSLY LIMITED TO THE DURATION • Exhaust gas recirculation (EGR) tube
OF THIS WRITTEN WARRANTY. CLARKE • Crankcase ventilation valve
MAKES NO OTHER EXPRESS WARRANTY, • Electronic control unit (ECU) if equipped
• Sensors associated with ECU operation
Page 32 of 35
• Emission control information labels
• Turbocharger (if equipped)
• Fuel limiting device

Parts/components that are scheduled to be replaced as

part of the required maintenance schedule will be
covered under the warranty provisions for a period of
time up to the first scheduled replacement point for
the subject parts/ components. Subsequent damage to
other engine components as a direct result of a
warrantable failure an exhaust emission part/
component will be covered under the warranty
provisions described herein.

As the heavy-duty off-road engine owner, you should

however be aware that Clarke may deny you
warranty coverage if your heavy-duty off-road engine
or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications. Only due
to the above reasons, the manufacturer may deny the
warranty coverage.

9.0 INSTALLATION & OPERATION DATA

(See clarkefire.com)

10.0 WIRING DIAGRAMS

(See clarkefire.com)

11.0 PARTS ILLUSTRATION DRAWING

(See clarkefire.com)

Page 33 of 35
12.0 APPENDIX (Alpha Index)

Subject Page
Subject Page

A
Air Cleaner 17-18, 30-31 H
Alternator 26, 30 Heaters, Engine 20, 25-26, 30
23
B I
Battery Cables 12 Installation Data *
Battery Recommendations 30 Installation Instructions 9-10
Belt Adjustment 26,30
L
C Lube Oil Recommendations 19-20, 31
Capacities 20-21 Lubricating Oil Volume 20
Coolant Recommendation 9-11,13,20-22,25-26,27-32 Lubricating System 19
Cooling System
Anti-Freeze Solutions 20 M
Cooling System Capacity 21-22 Magnetic Pickup 27-29
Cooling Water Supply (Loop) 22-25 Maintenance Schedule 30-31
Cooling Water Flow Requirements * Manual Operation 14-15, 19-26
Filling Procedure 21-22 Model Number Identification 4
Heat Exchanger 20-25, 31
Inhibitors 20-21 N
Maintenance 21-23, 30-33 Name Plate (Engine) 4
Water 20-26, 30-31
Crankcase Ventilation 18 O
Oil Filter 19-20, 31-32
D Oil Level Dipstick 19-20
Dipstick, Oil Level 19-20 Oil Pressure *
Driveshaft alignment 12-13 Oil Specifications/Recommendations 10, 19-20
Driveshaft Maintenance 12 Operation Data *
Overspeed Reset 14, 26-29
E Overspeed Verification 14, 26
Electrical System 26
Engine Models 4-5 P
Engine Protective Systems (overspeed) 26-30 Parts Illustrations *
Engine Start-Up Service 14 Parts Information 31
Exhaust System 17-19, 30 Preventive Maintenance Schedule 30-31

F
Filters: S
Air Cleaner 8,17,031-32, 35 Serial Number 4
Fuel 9-11, 15-17, 30-35 Shutdown Systems 22, 26-30
Lubricating Oil 9, 19-20, 31-35 Speed Switch (MECAB) 26-27
Fuel Specifications * Storage 9
Fuel System Operation 15
Bleeding 16
Pump, Injection 16-17, 30 T
Service 15-16, 25-26, 30-32
Technical Data *

W
G Warranty 11, 31-33
Governor Speed Adjustment 29-30
Wiring Diagram:
DC System 26
AC Heater Systems 26

* See clarkefire.com

Page 34 of 35
 Appendix “A”

SPARE PARTS KA4H MODELS

Clarke Engine Models KA4H-UFKA24 KA4H-UFKA34

Part Description Part Number Part Number

Oil Filter C04700 C04700
Elec. Fuel Pump Pre-Filter C021163 C021163
Fuel Filter C021098 C021098
Air Filter C031261 C031261
Alternator C072512 C072512
Fuel Injection Pump C021099 C021153
Heat Exchanger U051191 U051191
Starter Motor (12V) C072511 C072511
Switch, Oil Pressure C071884 C071884
Switch, Speed C071963 C071963
Switch, Coolant Temperature C051749 C051749
Thermostat C053108 C053108
Nozzle, Injector C021100 C021148

Page 35 of 35