11
If the engine was removed from storage in which temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898, "Cold Weather Recommendations Operation and
Maintenance".
Installation Instructions
The correct installation of the engine is very important to achieving optimum performance and extended
engine life. In this respect, the engine has certain installation requirements, which are critical to how it performs.
These requirements are generally associated with the cooling, exhaust, induction air, and fuel systems. This
section of the manual should be read in conjunction with the relevant Installation and Operation Data Sheets. If
there is any doubt about an installation, contact should be made with Clarke Customer Support giving exact
details of the problem. All installations should be clean, free of any debris and dry. Care should be taken to
ensure that there is easy access to the engine for maintenance and repair. The safety of personnel who may be
in the area of the engine when it is running is of paramount importance when designing the installation layout.
Secure pump set to foundation and complete installation in accordance with pump manufacturer’s instructions.
Perform engine to pump coupling alignment. Lubricate Falk coupling with supplied grease or driveshaft
universal joints with NLGI grade #1 or #2 grease at the (3) zerk fittings. (Refer to section 2.4.3 for specific
alignment instructions).
Install the heat exchanger discharge pipe (Engine with Heat Exchanger Cooling). The discharge pipe should be
no smaller than the outlet connection on the heat exchanger. Discharge water piping should be installed in
accordance with applicable codes. All plumbing connecting to the heat exchanger must be secured to
minimize movement by the engine. Cooling loop water pressure to the heat exchanger must not exceed the
limit that is stated on the heat exchanger supplied with the engine.
Install all engine cooling system draincocks and plugs.
Engine is typically provided with premixed coolant installed. If engine is not provided with coolant or there is a
need to top off, fill engine cooling system with Clarke Coolant 0C054129. The only acceptable substitute is
COOL-GARD II TY26575. Refer to Figure #7-3 in section 7.3.3 for cooling system capacity. Refer to section 7.3.4
filling procedure.
Engine is shipped with oil installed. For make-up oil specifications refer to section 6 Lubrication System.
Connect fuel supply and return line to fuel supply tank plumbing. Reference the Fuel System section of the
Installation and Operation Data in (See clarkefire.com), for piping size, maximum allowable fuel pump suction,
and maximum allowable fuel head requirements. Fill supply tank with #2 diesel fuel (ASTM D-975) or BS 2869
Class A2 “Red” diesel fuel, bleed supply system of air and check for leaks.
CAUTION: Biodiesel fuel is not recommended for stand-by equipment that can have minimal fuel consumption
(such as standby generators, fire protection, etc.). For standby applications, use only petroleum based diesel
fuel with Caterpillar approved fuel conditioners/ additives. For fuel conditioners/additives, check with your local
CAT dealer or Clarke. Fuel supply level must meet applicable code requirements. Do not use a copper based
or galvanized material for any component of a diesel fuel system. The fuel will chemically react with the zinc
resulting in clogged fuel filters and injector systems.
Remove protective covering on air cleaner element.
Connect jacket water heater (if supplied) to AC power source. Connect the supplied heater connection wire
directly to a customer supplied electrical junction box. The electrical supply requirements are indicated on the
connection box. Connect to the heater directly to the junction box at the end of the heater only. Supply wiring
should never be routed through the engine gauge panel. Severe damage to critical engine control components
could result. Energize heater only after step #4 is completed.
Connect exhaust system to flexible connection on the engine. The exhaust system plumbing must be supported
by the building structure and not the engine. The exhaust flexible connection is provided only for the purpose
of thermal expansion and vibration isolation, not for misalignment or directional change.
Make electrical DC connections between the engine gauge panel terminal strip (if supplied) and the controller
per the controller manufacturer’s instructions. Refer to the wiring diagram sticker located on the inside door of
the engine gauge panel for proper connection of the water solenoid.
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