Operation and Maintenance Instructions Manual

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Operation and Maintenance Instructions Manual

JU/JW MODEL ENGINES FOR

FIRE PUMP APPLICATIONS

This manual covers John Deere Engines prepared by Clarke for fire pump service

Clarke UK, Ltd. Unit 1, Grange Works

Lomond Road Coatbridge ML5 2NN

United Kingdom TELE: +44(0)1236 429946

FAX: +44(0)1236 427274

Clarke Fire Protection Products, Inc. 3133 E. Kemper Road Cincinnati, OH 45241 U.S.A.

TELE: +1.513.771.2200 Ext. 427 FAX: +1.513.771.5375

www.clarkefire.com

05/13 C13960 revAB

SUBJECT

CONTENTS

1.0 INTRODUCTION 1.1 IDENTIFICATION/NAMEPLATE 1.2 SAFETY/CAUTION/WARNINGS

2.0 INSTALLATION/OPERATION 2.1 TYPICAL INSTALLATION 2.2 ENGINE STORAGE 2.2.1 Storage Less than 1 year 2.2.2 Extended Storage Maintenance Procedure 2.3 INSTALLATION INSTRUCTIONS 2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 2.4.1 Listed Driveshaft 2.4.2 Driveshaft 2.4.3 Other Coupling Types 2.5 WEEKLY TEST 2.6 STARTING/STOPPING THE ENGINE 2.6.1 Special Notes to Equipment Installer of an LPCB Approved (LPS1239) Engine Model 2.6.2 To Start Engine 2.6.3 To Stop Engine

3.0 ENGINE SYSTEMS 3.1 FUEL SYSTEM 3.1.1 Bleeding the Fuel System 3.1.1.1 JU4/6 UF, NL 3.1.1.2 JU4/6 LP 3.1.1.3 JW6 UF, NL 3.1.2 Draining the Condensate from the Fuel Filter 3.1.3 Changing Fuel Filter Cartridge 3.1.3.1 JU4/6 UF, NL 3.1.3.2 JU4/6 LP 3.1.3.3 JW6 UF, NL 3.1.4 Fuel Tanks 3.1.5 JU Fuel Injection Pump Components 3.1.6 JW Fuel Injection Pump Components 3.2 AIR/EXHAUST SYSTEM 3.2.1 Ambient Conditions 3.2.2 Ventilation 3.2.3 Standard Air Cleaner 3.2.4 Crankcase Ventilation

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PAGE

5 5 6 11 11 12 12 12 12 14 14 14 17 17 17 17 17 19 20 20 20 20 21 21 22 22 23 23 23 24 24 25 25 25 25 26 26

3.2.4.1 Open Crankcase Ventilation

26

3.2.4.2 Crankcase Ventilation System

27

3.2.5 Exhaust System

28

3.3 LUBRICATION SYSTEM

28

3.3.1 Checking Sump Oil

28

3.3.2 Changing Engine Oil

28

3.3.3 Changing Oil Filter Cartridge

29

3.3.4 Oil Specification

29

3.3.5 Oil Capacities

30

3.4 COOLING SYSTEM

30

3.4.1 Intended Engine Operating Temperature

30

3.4.2 Engine Coolant

30

3.4.3 Water

30

3.4.4 Coolant Capacities

30

3.4.5 Coolant Inhibitor

31

3.4.6 Procedure for Filling Engine

31

3.4.6.1 Engines without Coolant Recovery Tank

31

3.4.6.2 Engines with Coolant Recovery Tank

32

3.4.7 Providing Raw Water Supply to the Engine Heat Exchanger

33

3.4.7.1 Raw Water Supply

33

3.4.7.2 Cooling Loop

33

3.4.7.3 Setting Raw Water Flow Rate

34

3.4.7.4 Raw Water Outlet

34

3.4.7.5 Raw Water Quality Strainers, Deterioration of Heat Exchanger (CAC)

35

3.4.7.6 Backflow Preventers

35

3.4.7.7 Raw Water Outlet Temperature

35

3.4.8 Flow Paths of Engine Cooling System

35

3.4.9 Important Service Notice

36

3.4.9.1 Water Pump Cavitation

37

3.5 ELECTRICAL SYSTEM

37

3.5.1 Wiring Diagrams

37

3.5.2 Checking Drive Belt Tension and Adjustment

37

3.5.3 Speed Switch

38

3.5.4 Magnetic Pick-Up

38

3.5.5 Mechanical Engine Control & Alarm Board (MECAB) Speed Switch Troubleshooting

38

3.5.6 Field Simulation of Pump Controller Alarms

40

3.6 ENGINE SPEED ADJUSTMENT

41

4.0 MAINTENANCE SCHEDULE

41

4.1 ROUTINE MAINTENANCE

41

5.0 TROUBLE SHOOTING

42

Page 3 of 51

6.0 PARTS INFORMATION

42

6.1 SPARES

42

6.2 ENGINE MAINTENANCE PARTS LIST

42

7.0 OWNER ASSISTANCE

42

8.0 WARRANTY

42

8.1 GENERAL WARRANTY STATEMENT

42

8.2 CLARKE WARRANTY

42

8.3 JOHN DEERE WARRANTY

43

8.3.1 Warranty Duration

43

8.3.2 Warranty Coverage

43

8.3.3 Emissions System Warranty

43

8.3.4 Obtaining Warranty Service

44

8.3.5 Warranty Extensions

44

8.3.6 Purchaser's Responsibilities

45

8.3.7 No Representations or Implied Warranty

45

8.3.8 Remedy Limitation

45

8.3.9 No Seller's Warranty

46

8.3.10 Additional Information

46

9.0 ATCM CALIFORNIA EMISSION REGULATIONS FOR STATIONARY ENGINES

46

10.0 INSTALLATION & OPERATION DATA (See Technical Catalog C13965)

47

11.0 WIRING DIAGRAMS (See Technical Catalog C13965)

47

12.0 PARTS ILLLUSTRATION (See Technical Catalog C13965)

47

13.0 APPENIX (Alpha Index)

48

APPENDIX "A"

49

Check factory availability for a manual in one of the following languages:

Spanish French German Italian

MP-7 C13961 MP-7 C13962 MP-7 C13963 MP-7 C13964

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 4 of 51

1.0 INTRODUCTION

SCOPE OF SUPPLY

The following paragraphs summarize the "Scope of Supply" of the Engine:

The CLARKE Engine supplied has been designed for the sole purpose of driving a stationary Emergency Fire Pump. It must not be used for any other purpose.

Shall not be subjected to Horsepower requirements greater than the certified nameplate rating (for UL/cUL/FM/LPCB only).

Engines must be sized to cover fully the 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 and technical catalog (C13965).

Periodic running checks to ensure functionality should be kept to a maximum of ? hour per week.

1.1 IDENTIFICATION/NAMEPLATE

Throughout this manual, the terms "Engine" and "Machine" are used.

The term "Engine" refers solely to the diesel engine driver as supplied by CLARKE.

The term "Machine" refers to any piece of equipment with which the engine might interface.

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: Engine Model, Serial Number, Rating and Date of Manufacture are shown on this identification plate. The JU Series identification plate is mounted on the flywheel housing at the rear of the engine. The JW Series identification plate is mounted on right rear engine mount.

Note that there are five types of identification plates, dependent on whether the engine is a "Non-Listed" or "Listed/Approved" Model. These are typical examples. (See Figure #1).

Clarke Identification Plates

USA Non Listed

USA Listed/Approved

UK Non-Listed

UK Listed/Approved

Figure #1

Page 5 of 51

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