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Clarke C32H User Manual

Clarke C32H
61 pages
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Operation and Maintenance
Instructions Manual
C32H MODELS
ELECTRONIC ENGINES
FOR
FIRE PUMP APPLICATIONS
This manual covers Caterpillar Engines
Prepared by Clarke
for fire pump service
Clarke Fire Protection Products, Inc. Clarke Fire Protection Products, Ltd.
100 Progress Place Unit 1, Grange Works
Cincinnati, OH 45246 Lomond Road
U.S.A. Coatbridge
ML5 2NN
United Kingdom
TELE: +1.513.475.3473
FAX: +1.513.771.0726
TELE: +44(0)1236 429946
FAX: +44(0)1236 427274
www.clarkefire.com
C138229
02/23
RevC

Table of Contents

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Clarke C32H Specifications

General IconGeneral
BrandClarke
ModelC32H
CategoryEngine
LanguageEnglish

Summary

Introduction

Model Numbering and Identification

Explains the structure and meaning of Clarke model numbers and their components.

Safety, Caution, and Warnings

Basic Rules

Provides fundamental recommendations to reduce risks to persons and property.

Precautions for Welding

Installation and Operation

Typical Installation

Shows a typical fire pump installation layout with numbered components.

Engine Storage

Provides instructions for storing engines for less than or more than one year.

Installation Instructions

Critical requirements for engine installation to ensure performance and life.

Specific Flywheel Coupling Alignment Instructions

Details procedures for checking and ensuring proper engine-to-pump coupling alignment.

Driveshaft Alignment Check

Provides step-by-step instructions for checking driveshaft alignment for parallel offset and angular tolerance.

Weekly Test Procedure

Procedure for performing a weekly operational test of the engine.

Starting and Stopping the Engine

Instructions on how to start and stop the engine using various controls.

Starting Engine for Test Purposes ("Soft Start")

Explains the "Soft Start" feature for reduced speed operation during testing.

Stopping the Engine

Instructions on how to stop the engine using the main pump controller or gauge panel.

Engine Gauge Panel Description

Explains the components and layout of the engine gauge panel.

ECM Selector Switch and Primary/Alternate ECM

Explains the function of the ECM selector switch and dual ECM operation.

Dual ECM Automatic Switching

Details the automatic switching process between dual ECMs.

Programming ECM with Automatic Switching Device

Procedure for programming ECMs with an automatic switching device.

Using the PowerView Gauge

How to use the PowerView gauge for viewing parameters and codes.

Main Menu Navigation

How to navigate the PowerView gauge display screens using menu options.

User Settings Adjustment

How to adjust user settings like brightness, contrast, units, and language on the gauge.

User Settings Configuration

Details on adjusting user-specific settings on the PowerView gauge.

User Gauges Adjustment

How to customize auxiliary parameters displayed on the PowerView gauge.

Fire Pump Parameters Display

Displays specific parameters for fire pump applications, if available.

Auxiliary Parameters Display

Information on customizing auxiliary engine and system performance data displays.

User Gauges Configuration

Explains how to select and replace gauges on the PowerView display.

Engine Settings Data

Information regarding engine settings, pre-set by Clarke, used for troubleshooting.

Accessing Stored Trouble Codes

Steps to view past diagnostic trouble codes (DTCs) from the engine ECM.

Accessing Active Trouble Codes

How to view current diagnostic trouble codes (DTCs) displayed by the engine.

Engine Shutdown Codes

Information on engine shutdown conditions, specifically overspeed.

Engine Systems

Fuel System

Covers specifications, testing, and maintenance of the diesel fuel system.

Diesel Fuel Specification

Details the required diesel fuel specifications and quality for optimal performance.

Bleeding the Fuel System

Procedures for bleeding air from the fuel system after maintenance or run-out.

Priming C32H Engine Series (after filter change)

Specific priming procedure for the C32H engine after secondary filter replacement.

Priming C32H Engine Series (when run out of fuel)

Steps for priming the C32H engine after the fuel tank has been depleted.

Changing the Fuel Filters (C32H Series)

Identifies fuel filter locations and instructions for changing primary and secondary filters.

Fuel Tanks Maintenance

Guidance on maintaining fuel tank levels to reduce condensation.

Air/Exhaust System

Covers air intake, ventilation, and exhaust system requirements.

Ambient Conditions for Testing

Discusses engine testing conditions and potential de-rating for site conditions.

Ventilation Requirements

Requirements for adequate ventilation for the engine and combustion system.

Standard Air Filter

Information on the single-stage disposable air filter, its maintenance, and restriction limits.

Crankcase Ventilation

Explains the crankcase ventilation system and vapor expulsion.

Exhaust System Installation

Guidelines for exhaust system installation to ensure performance and engine life.

Lubrication System

Details engine oil checks, changes, and filter replacement.

Checking Sump Oil Level

How to check the engine oil level using the dipstick.

Changing Engine Oil

Step-by-step instructions for draining and refilling the engine oil.

Changing Oil Filter Cartridge

Procedures for replacing the engine oil filter cartridge.

Cooling System

Information on engine coolant, water quality, capacities, and filling procedures.

Intended Engine Operating Temperature

Specifies the recommended operating temperature range for C32H engines.

Engine Coolant Guidelines

Guidelines for selecting suitable coolant mixtures and their basic requirements.

Water Quality for Coolant

Discusses water quality requirements for engine coolant and potential issues.

Coolant Capacities and Types

Lists coolant capacities for C32H models and recommendations for coolant types.

Coolant Inhibitor Importance

Emphasizes the importance of coolant inhibitors and their function.

Procedure for Filling Engine

Instructions for filling the cooling system and purging air pockets.

Raw Water Supply to Heat Exchanger

Explains the need for a clean raw water source for heat exchanger cooling.

Cooling Loop Description

Describes the standard NFPA 20 cooling loop piping and its components.

Setting Raw Water Flow Rate

Crucial steps for setting the correct raw water flow rate for engine cooling.

Raw Water Outlet Requirements

Requirements for raw water outlet flow, especially when discharging to a reservoir.

Strainers and Heat Exchanger Maintenance

Importance of cleaning strainers and potential issues with heat exchangers.

Backflow Preventers

Information on backflow preventers in cooling loops as per NFPA 20.

Raw Water Outlet Temperature Considerations

Considerations for waste water discharge temperature based on local codes.

Flow Paths of Engine Cooling System

Diagram illustrating the flow of coolant and raw water through the system.

Important Service Notice: High Coolant Temperature

Critical alert regarding high coolant temperature conditions and required actions.

Water Pump Cavitation Causes and Damage

Explains causes and potential damage from water pump cavitation.

Electrical System

Wiring Diagrams

Lists available wiring diagrams for the engine gauge panel.

Checking Drive Belt Tension and Adjustment

Instructions on how to check and adjust drive belt tension for proper operation.

Engine Overspeed Procedure

Actions to take in case of an engine overspeed condition and reset procedure.

Field Simulation of Pump Controller Alarms

Procedures for simulating various pump controller alarms for testing.

Battery Requirements

Specifies the required battery type and specifications for the engine.

Engine Speed Adjustment

Procedures for adjusting engine speed during start-up or operation.

Maintenance Schedule

Routine Maintenance Schedule

Outlines routine maintenance tasks based on engine usage, categorized by frequency.

Trouble Shooting

Diagnostic Trouble Codes (DTC's)

Explains types of DTCs and how they are displayed on the gauge.

Parts Information

Spare Parts Ordering

Information on ordering genuine Clarke spare parts, including required details.

Engine Maintenance Parts List

Directs users to Appendix A for a list of engine maintenance parts.

Owner Assistance

Warranty Information

General Warranty Statement

Outlines warranty responsibilities shared between Clarke and Caterpillar.

Clarke Warranty Details

Details the duration and coverage of Clarke's warranty for system components.

Caterpillar Warranty Reference

Refers to Appendix B for Caterpillar's limited warranty information.

Reference Data and Appendices

Installation and Operation Data

Reference data for installation and operation parameters.

Wiring Diagrams Reference

Reference to wiring diagrams available on the Clarke website.

Parts Illustration Drawings Reference

Reference to parts illustration drawings.

Appendix A: C32H Models Parts Matrix

Provides a matrix of parts for different C32H engine models.

Appendix B: Caterpillar Limited Warranty

Contains the full text of Caterpillar's limited warranty.

Appendix C: PLD Maintenance and Operation

Overview and Principles of PLD Operation

Introduces the Pressure Limiting Driver (PLD) system and its function.

PLD Model Identification/Nameplate

Explains how PLD equipped models are identified on the nameplate.

PLD Installation Instructions

Specific instructions for installing the PLD system components.

PLD Connections

Details how to make discharge and suction pressure connections for the system.

PLD Start-Up Inspection Instructions

Procedures for inspecting the PLD system during initial start-up.

Disabling VSPLC / VSSLC

Steps to disable the VSPLC/VSSLC for testing purposes.

Bleeding the PLD Speed Control System

Procedure to bleed air from the PLD speed control system.

Initial Start Up of PLD System

Instructions for the initial start-up of the engine with the PLD system.

Main Relieve Valve (MRV) Setting

Recommendation for setting the MRV cracking pressure relative to the PLD Set Point.

PLD System Monitoring

How to monitor system set points and real-time pressures via the PowerView gauge.

PLD Operation

Procedures for operating the PLD system.

Freeze Protection for PLD Unit

Advice on protecting the unit from freezing conditions.

PLD System Failure Mode

What happens if the PLD Speed Control System fails and how to resolve it.

Engine Systems (PLD)

Covers the electrical system relevant to PLD engines.

Electrical System (PLD)

Covers the electrical system relevant to PLD engines.

Wiring Diagram for PLD Engines

Refers to Figure #29 for wiring diagrams of PLD equipped engines.

PLD Maintenance

General maintenance tasks for the PLD system.

Weekly Exercise (PLD)

Record pump shutoff pressure and engine RPM weekly for reference.

PLD Troubleshooting

Problem solving specific to the PLD system.

Powerview Gauge Diagnostics (PLD)

Explains diagnostic codes for PLD system failures and low suction alarms.

PLD Contact Information

Provides contact details for parts and service inquiries.

Pressure Trimming Capability of PLD Models

Provides data on pressure trimming capabilities for PLD models.

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